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

1
College of Mechanical and Equipment Engineering, Hebei University of Engineering, Handan 056038, China
2
Department of Mechanical Engineering, Shanghai University of Engineering Science, 333 Longteng Road, Shanghai 201620, China
3
National Engineering Research Center for Equipment and Technology of Cold Rolling Strip, Yanshan University, Qinhuangdao 066004, China
*
Authors to whom correspondence should be addressed.
Sensors 2018, 18(7), 1988; https://doi.org/10.3390/s18071988
Received: 27 April 2018 / Revised: 11 June 2018 / Accepted: 15 June 2018 / Published: 21 June 2018
(This article belongs to the Special Issue Sensors for MEMS and Microsystems)
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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. View Full-Text
Keywords: shapemeter roll; sensor; reliability evaluation; reliability robust design; initial interference shapemeter roll; sensor; reliability evaluation; reliability robust design; initial interference
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).
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Wu, H.; Cui, G.; Zhang, D.; Liu, H. Reliability Evaluation and Robust Design of a Sensor in an Entire Roller-Embedded Shapemeter. Sensors 2018, 18, 1988.

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