Angle of Twist Determination in Rolled Round Profiles
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Solution Overview
Problem
Existing methods for determining the angle of twist in rolled round profiles are inaccurate due to the distance between measuring devices and the last roll stand, leading to unpredictable and unstable twisting, which complicates the adjustment of roller systems for achieving a perfectly round product.
Innovation Solution
A method that calculates the harmonic of the z-fold angular frequency for the contour of the round profile, determining the angle of rotation between the reference center and extreme values within specific angular ranges, allowing for precise determination of GT and DT values and thus the angle of twist.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If measuring devices are placed at a distance from the last roll stand, then the measurement process is simplified and easier to implement, but the angle of twist determination becomes inaccurate and unstable
Solution Approach 1:
The patent replaces direct mechanical/optical measurement of the angle of twist with a computational approach. Instead of measuring the twist directly at the roll stand, the system measures the contour of the round profile at a distance using laser scanners, then calculates the angle of twist through mathematical processing of the contour data. This substitution enables accurate measurement while maintaining ease of implementation.
Solution Approach 2:
The patent introduces the contour of the round profile as an intermediary element. Rather than measuring the angle of twist directly, the system measures the contour shape at a distance from the roll stand, then uses this contour information as an intermediate step to calculate the angle of twist. This intermediary approach allows measurement at a convenient distance while maintaining accuracy.
2Ease of operation
If the contour of the round profile is measured at a distance from the last roll stand, then the measurement setup is simpler, but the determined angle of twist becomes unpredictable and unstable
Solution Approach 1:
The patent replaces direct measurement of the angle of twist with a computational calculation based on contour measurements. By substituting the direct measurement approach with a mathematical calculation approach, the system achieves stable and reliable results even when measuring at a distance from the roll stand, where direct measurement would be problematic.
Solution Approach 2:
The patent uses the measured contour data as feedback to calculate the angle of twist. The system measures the contour shape, processes this information through mathematical algorithms, and derives the angle of twist from the contour characteristics. This feedback-based calculation approach ensures stable and predictable results regardless of the measurement distance.
3Ease of manufacture
If traditional measurement methods are used with laser scanners, then the measurement process is straightforward, but the angle of twist determination lacks precision due to the distance from the roll stand
Solution Approach 1:
The patent introduces the contour of the round profile as an intermediary measurement target. Instead of attempting to measure the angle of twist directly, the system measures the contour shape at a distance, then uses this contour information as an intermediate step to calculate the angle of twist with high precision.
Solution Approach 2:
The patent replaces direct angle measurement with contour measurement followed by computational calculation. This substitution allows the use of straightforward laser scanning while achieving precise angle of twist determination through mathematical processing of the contour data.
Data Source
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AI summary
The method involves providing a number of z rollers per roller block to calculate an outline of a round profile. A reference center is determined for curve of the outline, and rotative frequency of the curve is calculated according to harmonic wave z-kindles to provide a harmonic wave. A bracket position of one of the rollers of a final caliber or the roller block is selected, and the calculated harmonic wave is searched. A twisting angle is calculated between a direction from a reference center to an extreme value of the harmonic wave and zero degree of the bracket position.