Automated Calibration and Realtime Communication of Data, Problems, Damage, Manipulation, and Failure from a Network of Battery Powered Smart Guide Nodes Within a Rolling Mill

A system for use in a rolling mill comprising:

• (a) a roll holder housing a plurality of rollers;
• (b) a smart module coupled to the roll holder, the smart module comprising:
• (1) a power source powering the smart module;
• (2) a microcontroller;
• (3) a motor, the motor, based on instructions from the microcontroller, controlling a position of the plurality of rollers by moving the roll holder;
• (4) one or more position sensors, the one or more position sensors detecting the position of the roll holder;
• (5) a microphone for collecting sound data, wherein the microcontroller performs audio spectral analysis on the collected sound data, identifies, based on the audio analysis, one or more problems associated with the rolling mill, and
• (6) a communication module, the communication module communicating with a central controlling computer to:
• (i) communicate the position of the roll holder and other sensor data to the central controlling computer, (ii) receive instructions from the central controlling computer to control the position of the roll holder, and (iii) communicating the one or more problems identified based on audio analysis to the central controlling computer.