A Robust and Highly Integrated Laser Doppler Velocimeter for High-Precision Velocity Measurement of Hot-Rolled Bars Under Thermal Radiation

Real-time, non-contact velocity measurement of hot-rolled bars is critical for metallurgical process control, but conventional laser Doppler velocimetry (LDV) systems often fail in these environments. The intense broadband thermal radiation from targets up to 1000 °C, coupled with severe surface depolarization, overwhelms weak scattered signals in high-speed (up to 40 m/s) rolling zones. To address this issue, we developed a fully integrated, thermal-radiation-resistant LDV sensing system. Hardware optimization was achieved by eliminating polarized-light transmission and adopting a parallel-beam design, which significantly enlarges the laser overlap area and increases detection depth. Furthermore, a 1550 nm laser (100 mW) was coaxially combined with a 10 nm narrow-band filter to isolate the thermal background and boost signal strength. A customized workflow utilizing continuous Fourier transform (CFT) spectral refinement and energy centroid estimation was implemented to precisely extract the true Doppler shift. Performance evaluations show the system achieves an excellent signal-to-noise ratio (SNR) of 29,532. Allan variance analysis confirms a stable detection sensitivity of 0.003 m/s (0.1 s integration time), a local short-to-medium-term optimal limit of 1.6 × 10−4 m/s, and a statistical accuracy of 0.005 m/s. Finally, the system was successfully deployed on an industrial rolling mill production line. It provided reliable velocity feedback for mill speed adjustment, achieving a near-zero-tension rolling process and fundamentally resolving workpiece dragging, squeezing, and steel pile-up.