1.What are the specific methods and applicable scenarios for online automatic detection?
Machine vision system: uses linear/area CCD cameras and multi-angle light sources (such as bright field and dark field).
Core technology. It offers 100% coverage, real-time alarms, and automatic defect classification (such as periodic roller marks). Suitable for high-speed production lines, but requires sophisticated software algorithms.
2.What are the offline manual testing methods and applicable scenarios?
Surface quality instrument: integrated into the production line, often using the principle of laser or white light interference.
It can detect extremely subtle defects (such as embossing) and provide three-dimensional topographic data with extremely high accuracy.
This is a basic method that relies on the inspector's experience. It is prone to missed detections due to fatigue and is suitable for random sampling or verification of online test results.
3.What are the key features and methods of precision auxiliary analysis and testing?
Offline precision instruments: such as roughness testers and profilometers.
Used for quantitative analysis of the depth, cycle, and shape of roller prints, providing crucial data for locating problematic rollers.
4.How to calculate and associate suspected rollers?
Calculation formula: Circumference of the suspected roll = Defect cycle distance L
Scope of investigation: Suspect rolls mainly include all rotating parts in contact with the strip, such as work rolls, intermediate rolls, tension rolls, pinch rolls, guide rolls, and furnace rolls.
On-site verification: Take the calculated circumference value (or diameter D = L / π) to the production line and verify the actual circumference of each roll. The roll that best matches the calculated value is the root cause of the problem.
5.What are some practical suggestions and strategies?
Investment Recommendation: For modern continuous production lines, configuring an online automated surface inspection system is the preferred and trending approach. It enables real-time recording, classification, and periodic calculation of defects, significantly improving troubleshooting efficiency.
Combined Strategy: The most reliable approach is a combination of "online inspection (automatic alarm) + offline precision measurement (quantitative analysis) + manual review (final confirmation)."
Establishing Records: Creating records for all rollers on the production line, recording their dimensions, installation location, usage history, and maintenance records, can greatly shorten troubleshooting time.
Preventative Maintenance: Regularly and systematically cleaning and inspecting the entire roller system is the most economical and effective way to reduce roller marks.