Reliability Evaluation and Robust Design of a Sensor in an Entire Roller-Embedded Shapemeter

Abstract

The intermittence of the shape detection signal associated with an entire roller-embedded shapemeter roll, used in a seven-pass cold reversible rolling process, is considered. A transient interference at the sensor top surface and the distance between the sensor top surface and the roll outer surface are developed, and a sensor reliability evaluation model is derived. The reliability of the sensor is evaluated via the random perturbation method, and the reliability sensitivity of design variables is proposed. The analysis reveals that the reliability is smallest in the third rolling pass. Of the design variables considered, the initial interference exhibits the largest reliability sensitivity and has the greatest influence on the sensor reliability. A reliability robust design model of the initial interference is therefore developed. A new shapemeter roll is fabricated and tested in a 1050 reversible cold rolling mill. The test results are consistent with the theoretical results, thereby validating the proposed model. The selection of an appropriate initial interference provides an important means of overcoming the adverse effects associated with the thermal deformation of sensor contact surfaces.

Test Plan for the Verification of the Robustness of Sensors and Automotive Electronic Products Using Scenario-Based Noise Deployment (SND)

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Robust Optimization for Micromachine Design Problems Involving Multimodal Distributions

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Development of a virtual shapemeter based on a shape control model for continuous annealing

“…Besides, Isei et al (2019) developed a new shape meter, which used LED dot pattern projection method to realise accurate automatic flatness control (AFC). Wu et al (2014Wu et al ( , 2018aWu et al ( , 2018b have carried out research on temperature field, thermal deformation models, thermal reliability of the shapemeter roll based on heat transfer and thermal elasticity theory; the temperature difference, thermal displacement difference, and the interference fit value associated with the interference fit surfaces were derived from these models.…”