Sensor Plate Roll Alignment Monitoring in Roller Frames
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Solution Overview
Problem
Current methods for determining the position and alignment of rolls in roll stands are complex, time-consuming, and costly, often requiring mill standstill for wear plate measurement, which disrupts rolling operations.
Innovation Solution
A sensor plate with integrated measuring sensors arranged in a matrix adjacent to the plain bearing surface, capable of detecting forces and deformations, and an evaluation device to determine roll position and alignment in real-time, allowing for continuous monitoring during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional measurement methods using depth gauges are used to determine wear plate thickness, then measurement accuracy is achieved, but the rolling mill must stop operations and great effort is required
Solution Approach 1:
The patent replaces the mechanical depth gauge measurement system with an optical measurement system. A light source emits light through the wear plate, and a sensor detects the transmitted light intensity. The wear plate thickness is determined optically based on the light absorption characteristics, eliminating the need for mechanical contact and manual measurement operations.
Solution Approach 2:
The measurement system is integrated directly into the rolling mill structure, allowing automatic continuous measurement of wear plate thickness during normal operations. The system self-monitors the wear state without requiring external intervention or stopping the production process, enabling real-time feedback for maintenance scheduling.
2Manufacturing precision
If frequent manual measurements of wear plates are performed, then roll position accuracy is maintained, but operational time is lost and costs increase
Solution Approach 1:
The optical measurement system operates continuously during rolling mill operations, constantly monitoring wear plate thickness and indirectly tracking roll position changes. This continuous measurement approach replaces discrete manual measurements, ensuring roll position accuracy is maintained without interrupting production flow or losing operational time.
3Reliability
If manual inspection of wear plates is conducted, then wear state is detected, but the process is complex and costly
Solution Approach 1:
The complex manual inspection process involving depth gauges and multiple measurement points is replaced by a simple optical transmission system. The light source and sensor arrangement provides automatic wear state detection based on light intensity variations, significantly reducing operational complexity while maintaining or improving detection reliability.
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 precise and continuous monitoring of roll positions and alignments, preventing roll set and ensuring rolling stability without the need for frequent mill stoppages, thereby improving operational efficiency and reducing maintenance costs.
Implementation Method 1
the measuring sensors are not subject to wear on the plain bearing surface and on the other hand are able to detect the forces and/or expansions and/or deformations acting on the sensor plate
Implementation Method 2
which can be brought into contact with a component and is subject to wear during operation of a roll stand
Data Source
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AI summary
The invention relates to a device (20) and to a method for determining the location and/or position of a roller in a roller frame. The device comprises an evaluating device (A), which is signal-linked to the measurement sensors (10) of a sensor plate (1), from which the signal values of the individual measurement sensors (10) can be received. The evaluating device (A) is set up in respect of programming technology such that, in consideration of a surface, linear or point contact set on the slide bearing surface (2) of the sensor plate (1) by an adjacent component, the position of a roller with which this sensor plate (1) is associated, and/or the alignment of the associated roller axis of said roller relative to an associated roller stand of a roller frame and/or of another roller in the same roller frame can be determined.