Non-contact Speed Sensor for Rolling Mill Roll Control
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Solution Overview
Problem
Conventional motor speed control systems for rolling mills rely on motor speed sensors, which are not effective for directly detecting and controlling the speed of the rolling roll due to issues like roll cooling water, impact from materials, and sensor reliability, leading to inaccurate speed control.
Innovation Solution
A motor speed control device using a non-contact type speed sensor positioned close to the rolling roll to detect the roll rotation shaft angular speed, with a speed controller adjusting the motor speed to match a target value, and additional features like waterproofing and dust-proofing, as well as a selector switch for redundancy and dynamic weight assignment between roll and motor speed sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a contact type roll speed sensor is directly attached to the rolling roll, then the speed of the rolling roll can be directly detected, but the sensor is apt to be out of order due to roll cooling water, impact from materials, and high temperature
Solution Approach 1:
The patent introduces a non-contact type roll speed sensor that detects the speed of the rolling roll through electromagnetic induction or optical methods without direct physical contact. This intermediary detection method eliminates the harmful effects of roll cooling water, high temperature, and mechanical impact on the sensor, while still achieving accurate speed measurement of the rolling roll
Solution Approach 2:
The patent replaces the mechanical contact type speed sensor with a non-contact type sensor that uses electromagnetic fields or optical fields to detect rotation speed. This substitution eliminates mechanical contact between the sensor and the rolling roll, thereby avoiding the issues caused by cooling water, heat, and mechanical impact
2Duration of action of stationary object
If the rolling roll is detached for polishing and replaced, then the roll can be maintained, but the roll speed sensor must be detached and reattached each case
Solution Approach 1:
The non-contact type roll speed sensor is positioned near the rolling roll but not directly attached to it. This intermediary positioning allows the sensor to detect roll speed through the magnetic field or optical field generated by the rotating roll, eliminating the need to attach or detach the sensor when the roll is replaced for polishing
Solution Approach 2:
The non-contact sensor system can detect the speed of different rolling rolls without requiring reconfiguration or reattachment. The sensor universally detects rotation speed through field interaction, making it adaptable to roll replacements and maintaining consistent functionality across different roll instances
3Productivity
If a large impact is made on the rolling roll when a sheet or plate is passed through, then the rolling process is completed, but the roll speed sensor is apt to be out of order due to the impact
Solution Approach 1:
The non-contact type sensor detects roll speed through electromagnetic or optical fields without being in the direct path of material passage. This intermediary detection method isolates the sensor from the high-impact environment where sheets or plates are passed through the rolls, preventing impact damage while maintaining productivity
Solution Approach 2:
The patent replaces mechanical contact-based speed detection with non-contact field-based detection. This substitution removes the sensor from the mechanical impact zone, allowing high-speed rolling operations to proceed without exposing the sensor to damaging impacts from passing materials
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 setup allows for accurate and reliable direct control of the rolling roll speed, improving control accuracy and stability by avoiding sensor failures and environmental impacts, while providing redundancy and dynamic adjustment for optimal performance.
Implementation Method 1
a non-contact type speed sensor configured to be arranged at a position close to the rolling roll with spacing to a circumferential surface of the roll rotation shaft and to detect a roll rotation shaft angular speed
Data Source
AI summary
A motor speed control device for a rolling mill, which includes a rolling roll that rolls a metal material, a roll rotation shaft directly connected to the rolling roll, a motor rotation shaft that transmits power to the roll rotation shaft, and a motor that drives the motor rotation shaft, includes: a non-contact type speed sensor arranged at a position close to the rolling roll with spacing to a circumferential surface of the roll rotation shaft to detect a roll rotation shaft angular speed of the roll rotation shaft; and a speed controller that controls a speed of the motor based on a comparison value between an actual value and a target angular speed of the rolling roll so that the actual value coincides with the target angular speed. The actual value is the roll rotation shaft angular speed to be fed back to the speed controller.