Rolling Roll Crack Detection Using Shaft-Mounted AE Sensing
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Solution Overview
Problem
Existing crack detection methods for rolling rolls are complex and inefficient, requiring multiple sensors and substantial modifications to the rolling device, making it difficult to detect cracks online and prevent spalling destruction during steel sheet rolling.
Innovation Solution
An online crack detection device using an AE sensor in the shaft portion of the rolling roll to detect elastic waves, with a calculation unit filtering and quantizing the signals to distinguish between crack-induced and friction-induced elastic waves, allowing for real-time crack detection without continuous sensor disposition or device modification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are continuously disposed along the axial direction of the roll to detect cracks in the entire surface, then crack detection coverage is improved, but device complexity increases
Solution Approach 1:
The patent employs periodic action by detecting elastic waves at specific intervals during the rolling process rather than continuous monitoring. The AE sensor captures crack signals periodically as the roll rotates, achieving comprehensive detection coverage through strategic timing rather than continuous sensor disposition. This resolves the contradiction by maintaining detection precision while reducing device complexity through intermittent measurement.
Solution Approach 2:
The patent applies preliminary action by pre-positioning a single AE sensor in the shaft portion before the rolling process begins. The sensor is strategically located to detect elastic waves propagating from the barrel surface throughout the rolling operation, eliminating the need for multiple sensors or continuous adjustment. This preliminary placement achieves comprehensive coverage while simplifying the device structure.
2Measurement precision
If magnetic sensors are attached to the surface end portion of the rolling mill sleeve roll, then crack detection is enabled, but the rolling equipment configuration becomes complicated
Solution Approach 1:
The patent uses the roll shaft as an intermediary structure to house the AE sensor, eliminating the need for external magnetic sensors attached to the roll surface. The AE sensor detects elastic waves that propagate through the roll body from the barrel surface, using the roll structure itself as a transmission medium. This approach simplifies the overall equipment configuration by integrating the detection system into the existing roll structure rather than adding external components.
Solution Approach 2:
The patent replaces the magnetic sensor system with an acoustic emission-based detection system. Instead of using magnetic fields to detect surface cracks, the system uses elastic wave propagation through the roll material to detect cracks internally and on the surface. This substitution simplifies the equipment configuration by eliminating complex magnetic sensor attachments and support structures.
3Productivity
If AE sensor is used to detect elastic wave during rolling work, then online crack detection is achieved, but crack-related elastic waves are difficult to distinguish from noise
Solution Approach 1:
The patent implements feedback by continuously monitoring the rolling load and comparing it with detected elastic wave signals. When a crack occurs, the elastic wave detection timing correlates with specific rolling load conditions. This feedback mechanism allows the system to distinguish crack-related signals from noise by analyzing the temporal and contextual relationship between load variations and elastic wave detections, thereby maintaining high measurement precision during online operation.
Solution Approach 2:
The patent applies dynamics by adapting the detection strategy to the dynamic rolling process. The system monitors elastic waves in real-time during rolling operations, capturing signals that occur dynamically as the roll contacts the steel sheet. By analyzing the dynamic characteristics of elastic wave timing, amplitude, and frequency in relation to the rolling cycle, the system distinguishes crack signals from background noise, achieving both online detection capability and signal discrimination accuracy.
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 reliable online detection of crack occurrence and propagation, preventing roll breakage and reducing production losses by accurately discriminating crack-related elastic waves from noise, allowing for timely intervention and maintenance.
Implementation Method 1
an AE sensor detecting an elastic wave generated on a barrel surface
Data Source
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AI summary
A crack detection device performing online identification of the occurrence and propagation of a crack in the surface^p of the barrel portion of a rolling roll and a rolling roll provided with the crack detection function are provided without any substantial modification of a rolling device or the rolling roll and without any continuous disposition of multiple sensors in the rolling roll. The online crack detection device for a rolling roll incorporated in a rolling device with the rolling roll having a barrel portion and shaft portions extending as a unit from both ends of the barrel portion includes the rolling roll where an AE sensor detecting elastic waves generated on a surface of the barrel portion and a calculation unit calculating a characteristic quantity feature value of the elastic waves detected by the AE sensor are disposed in at least one of the shaft portions and a discrimination unit discriminating, from the characteristic quantity feature value, elastic waves attributable to a crack occurring in the barrel surface.