Patent Description:
A roller guide can mistakenly be calibrated to the wrong side (or incorrect hand: LH vs. RH) or installed on a stand of the wrong hand (in a two-strand rolling mill with opposite hand stands on each strand). This condition is not possible to detect by visual inspection, and the guide may be put into operation without the knowledge of the operators. Running in the mill in this flawed condition may cause early guide failure, unplanned mill downtime, and / or poor finished product quality. The disclosed methodology provides real time feedback and alerts to the operators if the guide is positioned incorrectly.

A roller guide can be manually manipulated after calibration while it is sitting idle before installation on the rolling mill. This condition is poor practice and is not readily obvious to other operators. The manipulated adjustment may lead to early guide failure, unplanned mill downtime, and / or poor finished product quality. The disclosed methodology provides real time feedback and alerts to the operators if the guide has been manipulated or manually adjusted after calibration.

A roller guide or other equipment in a rolling mill can sometimes have a problem that first presents itself as a change in sound. Some of these problems may be detected by the operators that are experienced in identifying these sound changes, but others may be missed or simply not obvious. The disclosed methodology provides a solution for real time sound identification of problems followed by an alert for the operators.

A roller guide can be inadvertently set for the wrong finished product size. This condition is not always readily obvious to the operators and would require very careful inspection to identify. Running in a mill in this condition may lead to early guide failure, unplanned mill downtime, and/or poor finished product quality. The disclosed methodology provides real time feedback to the operators if a guide is selected for use or put into use that is set to the wrong product prior to running the mill.

Adjustment and calibration of roller guides requires a good amount of manual labor to physically adjust the guides into the correct orientation. This process is time consuming and can lead to carelessness, mistakes, and general inconsistencies from one operator, one day, or even one guide to the next. The disclosed methodology provides automatic calibration and adjustment to the roller guides.

Each of the problems are currently performed manually and may only be identified by careful attention and individual inspection by the operators.

<CIT> to Bradshaw discloses a roller guide assembly for guiding a workpiece into a roll pass of a rolling mill. <FIG> depicts Bradshaw's roller guide assembly <NUM>. The guide assembly comprises: a rigid housing structure; a pair of roller holders <NUM> extending lengthwise of the housing structure on opposite sides of the intended direction of travel of the workpiece with compression springs <NUM> located in bores in the roller holders <NUM> (where the springs are captured in their respective bores via cover plates <NUM> and the housing structure further includes vertical pivots <NUM>); guide rollers <NUM> rotatably carried on the roller holders <NUM>, the guide rollers <NUM> defining a gap therebetween and being configured to engage and guide the workpiece into the roll pass of the rolling mill; pivots for mounting the roller holders on the housing structure for movement about axes extending generally parallel to the rotational axes of the guide rollers; springs for applying forces to the roller holders to rotate the roller holders about their respective axes in directions urging the guide rollers apart; and stops on the housing structure for resisting rotation of the roller holders, at least one of the stops acting through a force sensor to provide a measure of the force being applied to the respective roller holder. The spring-induced rotation of the roll holders <NUM> is resisted by stops comprising adjusting screws <NUM> positions to be contacted by load sensitive sensors <NUM>. The drive point <NUM> a is for manual adjustment, generally used for off-line setting of the guide.

<CIT> discloses a method and a device for the automatic adjustment of guide rolls in a guide box located upstream of a rolling mill stand to guide a rolled stock in direct cooperation with that stand. The positions of the guide rolls are adjusted in relation to the rolling pass of the stand via an adjustment unit that is connected to a source of power. An instrument is included to measure the actual dimensions of the rolled stock upstream of the guide rolls. Furthermore, a system for the memorised setting of the rolling rolls of a rolling mill stand that is positioned upstream of the guide rolls is functionally associated with the adjustment unit according to the required positioning of the guide rolls such that the actuation signals sent to the adjustment unit for the positioning of the guide rolls are correlated with the position of the rolling rolls of the rolling mill stand upstream of the guide box.

<CIT> discloses a guide box comprising independently movable roller holders. Target positions for the roller holders are transmitted to a position controller that detects the positions of the roller holders by means of encoders. The movement of the roller holders is operated by an arithmetic unit via the the position controller and hydraulic motors.

<CIT> discloses a gauge for use in obtaining correct alignment between a grooved roll of a rolling mill and an associated guide box. The guide box comprises a block configured to be pushed inwardly towards the roll, means on the inner end of the block arranged to enter the roll groove when the block is pushed inwardly, and a device connected with the said means and arranged to indicate whether or not the groove is correctly aligned with the guide box. The device can be a battery-operated lamp.

<CIT> discloses a method for detecting the generation of chattering in a cold rolling mill by detecting an acoustic waveform with a microphone in the vicinity of a cold rolling mill while the cold rolling mill is rolling a rolled material. The acoustic waveform is converted into an electrical signal from which a frequency band component characteristic of chattering is extracted. Chattering is determined to occur when the effective intensity of the extracted signal exceeds a set value.

Embodiments of the present invention are an improvement over prior art systems and methods.

In one embodiment, the present invention provides a system for use in a rolling mill comprising: (a) a roll holder housing a plurality of rollers; and (b) a smart module coupled to the roll holder, the smart module comprising: (<NUM>) a power source powering the smart module; (<NUM>) a microcontroller; (<NUM>) a motor, the motor, based on instructions from the microcontroller, controlling a position of the plurality of rollers by moving the roll holder; (<NUM>) one or more position sensors, the one or more position sensors detecting the position of the roll holder; and (<NUM>) a communication module, the communication module communicating with a central controlling computer to: (i) communicate the position of the roll holder and other sensor data to the central controlling computer, and (ii) receive instructions from the central controlling computer to control the position of the roll holder.

In another embodiment, the present invention provides a system for use in a rolling mill comprising: (a) a roll holder housing a plurality of rollers; (b) a smart module coupled to the roll holder, the smart module comprising: (<NUM>) a power source powering the smart module; (<NUM>) a microcontroller; (<NUM>) a motor, the motor, based on instructions from the microcontroller, controlling a position of the plurality of rollers by moving the roll holder; (<NUM>) one or more position sensors, the one or more position sensors detecting the position of the roll holder; (<NUM>) a microphone for collecting sound data, wherein the microcontroller performs audio spectral analysis on the collected sound data, identifies, based on the audio analysis, one or more problems associated with the rolling mill, and (<NUM>) a communication module, the communication module communicating with a central controlling computer to: (i) communicate the position of the roll holder and other sensor data to the central controlling computer, (ii) receive instructions from the central controlling computer to control the position of the roll holder, and (iii) communicating the one or more problems identified based on audio analysis to the central controlling computer.

The present disclosure, in accordance with one or more various examples, is described in detail with reference to the following figures. The drawings are provided for purposes of illustration only and merely depict examples of the disclosure. These drawings are provided to facilitate the reader's understanding of the disclosure and should not be considered limiting of the breadth, scope, or applicability of the disclosure. It should be noted that for clarity and ease of illustration these drawings are not necessarily made to scale.

Each of the problems are solved with the addition of a 'smart module' to the roller guide. <FIG> depicts a smart controller for a roller guide as per the teachings of the present invention. The smart module comprises a micro controller <NUM>, wireless communication module <NUM>, motor <NUM> (e.g., stepper motor(s)) for controlling the position of the rollers <NUM> by moving the roll holders <NUM>, an accelerometer <NUM>, that detects acceleration and orientation, position sensors <NUM> for sensing the position of the roll holders, a temperature sensor to measure temperature at one or more locations within the roller guide, and a microphone <NUM>. The accelerometer is used to determine the orientation of the roller guide in space by measuring acceleration due to gravity across three axes. When sitting level, the z-axis will measure the full effect of gravity, as the guide is tilted to one side. One of the other axes will start to measure some of the effect of gravity. This data is used to calculate angular position of the guide. The accelerometer is also measuring acceleration amplitude in general for the X, Y, and Z axes, so a determination can be made if there is a problem that manifests as an increase in vibration.

It is also noted that in one embodiment, the accelerometer data is used to detect if the roller guide mounting has become loose during rolling. In this scenario, the operator will be unaware of the loose mounting situation because the cover of the mill is closed during operation. If the accelerometer shows a change in orientation during operation, the central controlling computer will alert the operator that the guide may have become loose from its mounting.

The temperature sensor can measure the overall ambient temperature inside the smart module or the bulk temperature of the guide itself depending on mounting location. If the guide has a certain kind of problem, and the bulk temperature of the guide or ambient air starts to increase, the temperature sensor will detect this change, and will alert the operator as necessary. This will be used in conjunction with other sensor data, like the microphone and accelerometer to help determine what the problem is, and if it is severe enough to shut the mill down to investigate.

The smart module is powered by a rechargeable battery <NUM>, which allows complete wireless operation in the rolling mill, and it is fitted with a multi-color LED <NUM>, to indicate various alerts or states.

<FIG> depicts a pair of roll holders. Typically, a pair or rollers are standard, where one roller is held in each roll holder. Occasionally, two rollers for each roll holder may also be used.

The accelerometer is used to detect the orientation of the guide in space, specifically it is used to detect if the guide is mounted on the correct hand (LH vs. RH) stand. The stands are oriented at a <NUM>-degree angle to each other, and generally at a <NUM>-degree angle to the ground, so the signal from the accelerometer is used to detect if the guide is mounted to a LH stand or a RH stand. The accelerometer is also used to detect vibration in the guide, specifically vibration from the rollers / bearings to determine if they have failed.

The overall arrangement of how such a system would be set up in a rolling mill is shown in <FIG>. Multiple guides fitted with smart modules 202A through 202C, which are mounted in position on the rolling mill <NUM>. The smart modules simultaneously communicate to and from a nearby central controlling computer <NUM>. The central computer can set the operational mode of each smart module, send a command to move guide rollers, as well as receive data from the smart modules including sensor data, warnings, and general information.

Prior to installation on the rolling mill, the roller guides are calibrated on an offline alignment station <NUM>, which is also a computer-controlled system. The offline alignment station can also communicate with the smart modules.

<FIG> illustrates the calibration process, in which the offline alignment station <NUM>, sends positional information to the smart module <NUM>, which in turn automatically adjusts the position of the guide rollers to their correct position. Once calibration is complete, the offline alignment station communicates a variety of setting information, including roller position, product size, mounting hand, stand number, etc. to the smart module which saves this data to its memory.

In one embodiment, the present invention provides a system for use in a rolling mill comprising: (a) a roll holder housing a plurality of rollers; (b) a smart module coupled to the roll holder, the smart module comprising: (<NUM>) a power source powering the smart module; (<NUM>) a microcontroller; (<NUM>) a motor, the motor, based on instructions from the microcontroller, controlling a position of the plurality of rollers by moving the roll holder; (<NUM>) one or more position sensors, the one or more position sensors detecting the position of the roll holder; and (<NUM>) a communication module, the communication module communicating with a central controlling computer to: (i) communicate the position of the roll holder and other sensor data to the central controlling computer, and (ii) receive instructions from the central controlling computer to control the position of the roll holder.

The position of the rollers via the position sensors is stored on the smart module memory so the smart module can notify the operators if changes have been made after calibration. When the smart module is powered on, the microcontroller continuously compares the current output of the position sensors to the stored values. If a change (over a prescribed threshold) has been detected, the smart module will give an indication, such as having the built in LED flash red.

The product size that each guide is set for is stored on the smart module memory from the calibration process. Before guides can be used in the rolling mill, they must be synched via a handshake with the central controlling computer. This handshake transfers the data stored in the smart module memory to the central computer and sets the guide into a 'ready for use' mode. The operator must select the product that is being rolled on the central computer before synching any guides to the rolling campaign. If an operator tries to add a guide that is set for a different product, the operator will be alerted of the problem.

The mounting hand is stored because the calibrated hand must match the hand that the guide is mounted in the rolling mill. When the roller guide is ready to be installed onto the rolling mill, the power for the smart module is turned on. Once powered, the microcontroller continuously reads the orientation data from the accelerometer and compares it to the calibrated hand. If the orientation matches the calibrated hand, the smart module will give an indication, such as turning the built in LED green. If the orientation is opposite the calibrated hand, the smart module will give an indication, such as having the built in LED flash red.

When the roller guide is mounted in the rolling mill an operator can send a command via the central computer to start detecting problems using sound. The smart module collects sound data from the microphone and performs an audio spectral analysis with Fast Fourier Transform. The smart module transmits the spectral component data to the central computer, which analyzes the data for potential problems. If a problem is identified, the operator is notified.

Although position sensors <NUM> are shown in <FIG>, other sensors are also envisioned in addition to the position sensors <NUM>. For example, in one embodiment, the accelerometer block <NUM> or the position sensor block <NUM> could additionally include a temperature sensor that may be used to identify problems in the rolling mill. Alternatively, the temperature sensor could be an independent sensor mounted anywhere in the structure shown in <FIG>.

Advantages of the present invention include fewer guide failures, superior finished product quality, less rolling mill downtime, longer useful life of guiding equipment, and less manpower required to maintain and monitor the roller guides as compared to the prior art solution.

Specifically, the feature of adding a smart module to the guide with embedded sensors and wireless communication to a central computer allows the described advantages to be performed.

Another advantage of the present invention involves the ability to retrofit or upgrade existing mills.

A different configuration of sensors and actuators could potentially also solve the problems. Additionally, the communication could be completely wired as opposed to wireless, and the smart modules could be powered by main line power rather than individual batteries.

In one embodiment, the smart modules communicate with each other as well as with the central controlling computer. This would allow in certain situations for the guides to instruct each other to do something in the event of a failure, or allow for a particular application without a central controlling computer, or just generally improve the efficiency of the system.

In another embodiment, there is no need for a central controlling computer, as the smart module made adjustments and decisions on its own and operated in an autonomous manner but could optionally still communicate with other smart modules. This configuration could still have a central display screen that would show information from the smart module(s). Smart modules may communicate to each other via wireless communication, in the same way they communicate to the central controlling computer. It could also be done via a wired connection. There are several situations where communication between smart modules can be advantageous. An example of such a situation is where relatively large distances exist between smart modules (in a mill where multiple mill locations exist that utilize smart guides), and direct communication between a guide and the central controlling computer may not be possible. In this case, a cascading of commands could be achieved by sending a communication to one smart module, which would in turn direct other smart modules to do something. Another area where direct communication would be advantageous is that it simplifies the communication that is necessary between the central controlling computer and the guides. For example, if all five guides in a mill are to be activated, a command may be sent to each guide to activate the guide to begin sending sensor data to the central controlling computer. In a scenario where one of the guides is defined as a 'master', we could send the activate command to that one guide, which in turn would send the activate command to the four other guides (which are 'slaves') in the mill. Ideally, a system would have a combination of both central computer to guide communication and direct guide to guide communication. Communication between smart modules can be done with the same equipment.

The above-described features and applications can be implemented as software processes that are specified as a set of instructions recorded on a computer readable storage medium (also referred to as computer readable medium). When these instructions are executed by one or more processing unit(s) (e.g., one or more processors, cores of processors, or other processing units), they cause the processing unit(s) to perform the actions indicated in the instructions. Embodiments within the scope of the present disclosure may also include tangible and/or non-transitory computer-readable storage media for carrying or having computer-executable instructions or data structures stored thereon. Such non-transitory computer-readable storage media can be any available media that can be accessed by a general purpose or special purpose computer, including the functional design of any special purpose processor. By way of example, and not limitation, such non-transitory computer-readable media can include flash memory, RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code means in the form of computer-executable instructions, data structures, or processor chip design. The computer readable media does not include carrier waves and electronic signals passing wirelessly or over wired connections.

Computer-executable instructions include, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing device to perform a certain function or group of functions. Computer-executable instructions also include program modules that are executed by computers in stand-alone or network environments. Generally, program modules include routines, programs, components, data structures, objects, and the functions inherent in the design of special-purpose processors, etc. that perform particular tasks or implement particular abstract data types. Computer-executable instructions, associated data structures, and program modules represent examples of the program code means for executing steps of the methods disclosed herein. The particular sequence of such executable instructions or associated data structures represents examples of corresponding acts for implementing the functions described in such steps.

The essential elements of a computer are a processor for performing or executing instructions and one or more memory devices for storing instructions and data. Moreover, a computer can be embedded in another device.

In this specification, the term "software" is meant to include firmware residing in read-only memory or applications stored in magnetic storage or flash storage, for example, a solid-state drive, which can be read into memory for processing by a processor. Also, in some implementations, multiple software technologies can be implemented as sub-parts of a larger program while remaining distinct software technologies. In some implementations, multiple software technologies can also be implemented as separate programs. Finally, any combination of separate programs that together implement a software technology described here is within the scope of the subject technology. In some implementations, the software programs, when installed to operate on one or more electronic systems, define one or more specific machine implementations that execute and perform the operations of the software programs.

These functions described above can be implemented in digital electronic circuitry, in computer software, firmware or hardware. The techniques can be implemented using one or more computer program products. Programmable processors and computers can be included in or packaged as mobile devices. The processes and logic flows can be performed by one or more programmable processors and by one or more programmable logic circuitry. General and special purpose computing devices and storage devices can be interconnected through communication networks.

Some implementations include electronic components, for example microprocessors, storage and memory that store computer program instructions in a machine-readable or computer-readable medium (alternatively referred to as computer-readable storage media, machine-readable media, or machine-readable storage media). Some examples of such computer-readable media include RAM, ROM, read-only compact discs (CD-ROM), recordable compact discs (CD-R), rewritable compact discs (CD-RW), read-only digital versatile discs (e.g., DVD-ROM, dual-layer DVD-ROM), a variety of recordable/rewritable DVDs (e.g., DVD-RAM, DVD-RW, DVD+RW, etc.), flash memory (e.g., SD cards, mini-SD cards, micro-SD cards, etc.), magnetic or solid state hard drives, read-only and recordable Blu-Ray® discs, ultra-density optical discs, any other optical or magnetic media, and floppy disks. The computer-readable media can store a computer program that is executable by at least one processing unit and includes sets of instructions for performing various operations. Examples of computer programs or computer code include machine code, for example is produced by a compiler, and files including higher-level code that are executed by a computer, an electronic component, or a microprocessor using an interpreter.

While the above discussion primarily refers to microprocessor or multi-core processors that execute software, some implementations are performed by one or more integrated circuits, for example application specific integrated circuits (ASICs) or field programmable gate arrays (FPGAs). In some implementations, such integrated circuits execute instructions that are stored on the circuit itself.

Claim 1:
A system for use in a rolling mill (<NUM>) comprising:
(a) a roll holder (<NUM>) housing a plurality of rollers (<NUM>);
(b) a smart module (202A, 202B, 202C) coupled to the roll holder (<NUM>), the smart module (202A, 202B, 202C) comprising:
(<NUM>) a power source powering the smart module (202A, 202B, 202C);
(<NUM>) a microcontroller (<NUM>);
(<NUM>) a motor (<NUM>), the motor (<NUM>), based on instructions from the microcontroller (<NUM>), controlling a position of the plurality rollers (<NUM>) by moving the roll holder (<NUM>);
(<NUM>) one or more position sensors (<NUM>), the one or more position sensors (<NUM>) detecting the position of the roll holder (<NUM>); and
(<NUM>) a communication module (<NUM>), the communication module (<NUM>) communicating with a central controlling computer (<NUM>) to: (i) communicate the position of the roll holder (<NUM>) to the central controlling computer (<NUM>), and (ii) receive instructions from the central controlling computer (<NUM>) to control the position of the roll holder (<NUM>); and.