How to monitor the running status of the strip rollers to avoid overloading?

Install sensors for real-time monitoring

• Pressure sensor monitors rolling force: Installing pressure sensors on the bearing seat, archway and other positions of the strip roller can accurately measure the pressure on the strip roller during the strip rolling process in real time. Rolling force is a key indicator for judging whether the strip roller is overloaded. Once the pressure value exceeds the normal working range, there may be an overload risk, and the system will issue an early warning signal.

• Torque sensor monitors torque: Installing a torque sensor on the drive shaft or connection part of the strip roller can monitor the torque borne by the strip roller during rotation in real time. The magnitude of the torque directly reflects the load of the strip roller. When the torque suddenly increases or remains at a high level, it indicates that the strip roller may be overloaded.

• Vibration sensor monitors vibration: Install a vibration sensor on the roller body or bracket of the strip roller to judge the operating status of the strip roller by monitoring the amplitude, frequency and other parameters of the vibration. During normal operation, the vibration of the strip roller is relatively stable. If abnormal vibration occurs, it may be caused by uneven load, bearing failure or uneven strip material, which may cause overload.

Directly observe the operation status

• Observe the appearance of the strip: During the production process, operators should regularly observe the flatness and thickness uniformity of the strip. If the strip has obvious uneven thickness, wavy edges, warping, etc., it may be that the strip rollers are unevenly stressed or overloaded, causing the roller shape to change, affecting the rolling quality of the strip.
• Check the surface of the strip roller: Stop the machine regularly to check the surface of the strip roller to see if there is any damage such as wear, scratches, cracks, etc. Uneven wear or severe scratches or cracks in some parts may mean that the strip roller is under excessive local pressure during operation, which may cause overload risks.
• Listen to the sound of the equipment running: judge the running status by listening to the sound of the plate and belt roller during operation. Under normal circumstances, the running sound of the plate and belt roller is smooth and uniform. If there is abnormal noise, vibration or friction sound, it may indicate that the plate and belt roller is overloaded, the bearing is damaged, the lubrication is poor, etc.

Data analysis and system monitoring

• Collecting operating parameters: Using the data acquisition system, real-time collection of the belt roller’s speed, temperature, current, voltage and other operating parameters. These parameters are closely related to the belt roller’s load. For example, a sudden increase in current often means an increase in motor load, which may be caused by the belt roller overload.
• Establish a monitoring system: Build a comprehensive monitoring system to centrally display and analyze the data collected by various sensors and equipment operating parameters. Through the monitoring system, operators can understand the overall operating status of the strip roller in real time. The system can also set thresholds and automatically alarm when the data exceeds the threshold.
• Data analysis: Use data analysis software to analyze the large amount of data collected, establish a mathematical model of the strip roller operation status, and timely discover potential overload risks through comparative analysis, trend analysis, etc. For example, analyze the trend of rolling force over time. If the rolling force shows a continuous upward trend and approaches or exceeds the set safety value, measures need to be taken to adjust production parameters or check equipment.