Rolling Mill Sensor Unit for Gap Measurement
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Solution Overview
Problem
Current rolling mills face challenges in achieving high accuracy in controlling the uniform thickness of products manufactured by ensuring precise gap maintenance between rolls, which affects the quality of the sheet-like products produced.
Innovation Solution
A rolling mill equipped with a sensor unit that includes a distance sensor with an extension/contraction part, allowing for direct measurement of the gap between rolls, and a control unit that adjusts the roll positions based on this measurement, ensuring high accuracy in gap detection and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a non-contact type distance sensor is used to measure the gap between rolls, then the device complexity is reduced and ease of operation is improved, but the measurement precision is insufficient (accuracy of 10 µm or more)
Solution Approach 1:
The patent replaces non-contact optical distance sensors with a contact-type mechanical sensor unit that directly measures the gap between rolls through physical contact. This mechanical substitution achieves superior measurement precision (1 µm or more) by eliminating optical interference and improving signal stability, though it increases device complexity through the need for contact surfaces and mechanical coupling structures.
Solution Approach 2:
The sensor unit introduces intermediary components including extension/contraction parts, sliding parts, and contact surfaces that mediate between the rolls and the measurement system. These intermediaries transmit mechanical displacement from the roll gap to the distance sensor, enabling high-precision measurement while isolating the sensor from direct thermal and mechanical stress of the rolling process.
2Manufacturing precision
If the gap between rolls is not precisely controlled, then the device complexity is reduced, but the manufacturing precision of product thickness deteriorates
Solution Approach 1:
The patent implements a closed-loop feedback control system where the sensor unit continuously measures the gap between rolls and transmits this information to a control unit. The control unit adjusts the roll gap in real-time based on the measured values, ensuring consistent product thickness. This feedback mechanism achieves high manufacturing precision (1 µm or more thickness uniformity) but increases device complexity through sensors, signal processing circuits, and control algorithms.
3Measurement precision
If a contact-type sensor unit is used to improve measurement precision, then the measurement precision improves (accuracy of 1 µm or more), but the reliability decreases due to wear and contact issues
Solution Approach 1:
The sensor unit incorporates flexible sliding parts and contact surfaces that can accommodate minor misalignments and variations in roll surface geometry. The sliding mechanism allows the contact surfaces to move smoothly along the roll surfaces, reducing friction and wear. This design maintains high measurement precision while improving reliability by preventing sensor jamming and extending service life through self-adjusting contact interfaces.
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 solution enables precise detection and control of the gap between rolls, resulting in significantly improved uniformity of product thickness, surpassing the accuracy of traditional non-contact distance sensors by achieving measurements around 1 µm compared to 10 µm or more.
Implementation Method 1
a distance sensor including an extension/contraction part configured to extend and contract in one direction in which the first and second axle boxes are aligned
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
A calender includes: first and second rolls adjacent to each other; a first axle box rotatably supporting a shaft of the first roll; a second axle box rotatably supporting a shaft of the second roll and adjacent to the first axle box; an adjustment part that adjusts a position of the first axle box so as to bring the first roll and the second roll close to or apart from each other; a sensor unit interposed between the first axle box and the second axle box and in contact with both the first axle box and the second axle box; and a controller. The sensor unit includes: a distance sensor including an extension/contraction part that extends and contracts in a direction in which the first and second axle boxes are aligned; a first member holding the distance sensor; and a second member abutting on the extension/contraction part and attached to the first member slidably along an extension/contraction direction of the extension/contraction part. The controller controls the adjustment part based on an extension/contraction amount of the extension/contraction part.