Cone Roller Machine

We are a professional manufacturer of Cone Rollers with more than 10 years of industry experience. Today, we would like to introduce you to the current status of the application of in-line measurement technology for Cone Rollers:

As a key equipment for metal plate forming and processing, the Cone Roller is widely used in the manufacturing fields of pressure vessels, wind turbine towers, chemical pipelines and so on. With the improvement of industrial automation level, online measurement technology is gradually applied to the process of Cone Roller, which effectively solves the problems of low efficiency and lack of precision of traditional manual inspection. At present, the technology has achieved real-time monitoring of key parameters such as rolled diameter, taper, roundness, etc., which significantly improves product quality and production efficiency.

In the process of Cone Roller, the online measurement system mainly obtains the dimensional data of the workpiece by laser scanning or visual inspection. Laser displacement sensors are installed near the roll axis of the Cone Roller, scanning the curvature of the plate in real time and transmitting the data to the control system. The visual measurement system captures the contour of the workpiece with an industrial camera, which is combined with image processing algorithms to calculate the moulding dimensions. These non-contact measurement methods avoid the mechanical contact errors of traditional caliper and sample inspection, while reducing production downtime. Some high-end Cone Roller have achieved closed-loop control of measurement and processing, and the system is able to automatically adjust roll pressure parameters based on real-time measurement data to ensure that the forming accuracy is stable within the process requirements.

The application of online measurement technology in thick plate rolling is particularly effective. The rebound amount is large when forming thick plates, and the traditional process relies on the operator's experience to make repeated adjustments, resulting in low processing efficiency. After the integration of online measurement system, the equipment can automatically detect the amount of springback deformation, and through the algorithm to predict the compensation value, directly correct the roller pressure and feed speed. The practice of a heavy equipment manufacturer shows that when a thick-walled cylinder is processed by a roll cone machine with online measurement, the roundness error of the product is controlled within 0.5 mm, which is more than 40% higher than the accuracy of the manual inspection method. In addition, the system can also record historical processing data, providing reference for process optimisation of similar products.

In the field of thin-walled parts processing, online measurement technology mainly solves the problems of plate wrinkling and surface scratching. High-precision laser sensors can detect the stress distribution of the plate during the coiling process, and when the local deformation exceeds the threshold value, the system immediately triggers an alarm and suspends processing. Some of the advanced systems are equipped with infrared cameras that monitor changes in the temperature of the sheet to anticipate the risk of cracking. These features significantly reduce the scrap rate of thin-walled parts, and are particularly suitable for processing deformation-prone materials such as stainless steel and aluminium alloys.

At present, the promotion of online measurement technology for cone rollers still faces certain challenges. High temperature, oil and other harsh working conditions easily affect the measurement stability of optical sensors, which need to be cleaned and calibrated regularly. Three-dimensional dimensional measurement of complex curved workpieces puts high demands on the processing speed of the algorithm, and there is a data delay phenomenon in some systems. In addition, small and medium-sized enterprises are more sensitive to the investment cost of on-line measurement equipment, and are more inclined to choose the segmented sampling programme.

At present, the promotion of online measurement technology for Cone Roller still faces certain challenges. High temperature, oil and other harsh working conditions easily affect the measurement stability of optical sensors, which need to be cleaned and calibrated regularly. Three-dimensional dimensional measurement of complex curved workpieces puts high demands on the processing speed of the algorithm, and there is a data delay phenomenon in some systems. In addition, small and medium-sized enterprises are more sensitive to the investment cost of on-line measurement equipment, and are more inclined to choose the segmented sampling programme.

From the perspective of technology development trend, multi-sensor fusion will become the development direction. By combining laser scanning, visual inspection and strain measurement, the system can obtain more comprehensive information about the state of the workpiece.The application of 5G technology is expected to solve the problem of real-time transmission of massive measurement data, while edge computing can improve the efficiency of local data processing. In the future, as the maturity of intelligent manufacturing increases, the online measurement technology for Cone Roller will be deeply integrated with systems such as digital twins and predictive maintenance, further promoting the transformation of metal-forming processing to intelligence.

Overall, online measurement technology for Cone Rollers has evolved from single size inspection to whole process quality control. Its real-time and high-precision features not only improve product consistency, but also provide data support for process optimisation. Although the adaptability and cost still need to be improved, the technology has become a standard feature of high-end Cone Roller and will play a more important role in the digital transformation of the manufacturing industry.

If you are interested in Cone Rollers, please contact us.