steelmaster - zumbach...steelmaster non-contact in-line dimension measurement in the steel industry....
TRANSCRIPT
STEELMASTER
Non-Contact In-line Dimension Measurement in the Steel Industry.Dependable Solutions for Hot Rolling and for Quality Control.
L
2
Wire Rod, Bar, Rebar, Profile, Tube, Pipe – Hot, Cold, Quality Control
•Closertolerances(1/2,1⁄4DIN)•"Zerofault"•100%qualitycontrol•Higherproductivity•Fasterstartup•Lessdowntime•Lessmanpower
Toremaincompetitiveasasteelmanufacturer, the latestand most advanced technologies are needed to ensurethe best product quality and maximum output. Amongothers,onechallenge is toobtainkeydatawhichallowsto increase the productivity and improveproduct qualitywhilstremainingcosteffective.
STEELMASTER gauges and systems. They are based onlatest technologyandon theexperiencewithmore than300unitsinhotrollingandsimilarprocessesandtheyarebacked by many thousand ODAC scanners, operating incoldprocesses.
Outstanding AdvantagesForeasyintegration,dependableoperation,dataprocessinganddisplay:•Hi-Techlaserscannerswithutmostprecision•Upto6000measurements/s•Onesingle(fibreoptic)cablebetweenLPOandCPO•CompactindustrialPCwithhighestworkingreliability•HighlydevelopedSTEELMASTERsoftware•Specialsoftwaresolutionsforpolygonalshapes•Sophisticatedmechanicsandprotectionsystem•Closetozeromaintenance–quickandeasycleaning
Modernin-linemeasuringsystemsnotonlyprovideaccuratevaluesfordiameter,ovality,width,heightetc.,buttheyalsodetectshapedeviations,rollingfaultsandotherprocessproblemsinstantly.STEELMASTERsystemseasilymeettheserequirementsthankstohighmeasuringrates,intelligentsoftwareandoscillatingorrotatingmeasuringmodesandothers.
Dimension Measurement
Longitudinalfaults
Shape Deviations, FaultsRadialfaults
Upto1000measurements/s(optionally2000measurements/s)
At100m/s L=100mm/4in.(optionally50mm/2in.)
Diameters canbemeasured in1orinupto6axes.Alsocombinedwithoscillation. Outsidedimensionsanddiagonalsaremeasuredaccuratelyandindependentofproductorientation(twist).
DIMENSIONMEASUREMENTANDFAULTDETECTION
WHATTHEMARkETDEMANDS OURSOLUTIONS
3
ExactmeasurementofD1...D4,blindzonesbetweenmeasurementaxes
SMO... Oscillating GaugesTheyareable tomeasureroundandnon-roundproductssuchassquares,hexagons,flatsetc.,independentoftwistand twist angle.This is made possible through dynamicregressionanalysiswithsophisticatedsoftware.Dependingonthemodel,thenumberofmeasurementaxes(scanners)canbe2,3,4or6.With an increasing number of axes, more data can becaptured at the same time, and the measurement cycleperprofileisshorter.SMOgaugescanalsobeoperatedinstaticmode,inselectableorientation.
Outstanding Advantages• Measuresalltypesofproducts• Independentoftwist• Veryshortmeasurementtimes• Alsocomputescrosssection(area)
SMS... Static GaugesSimple, compactandprimarily suited for roundproducts.SMSunitsareofthesamedesignasSMOsystems,withtheexceptionoftheoscillationmechanism.Theyareextremelycompactandeasytointegrate.
Dependingonthemodel,thenumberofmeasurementaxes(scanners)canbe2,4or6;othermodelsonrequest.
Outstanding Advantages• Extremelycompact• Veryhighmeasuringrate• Nomovingparts
α=upto180°
1to6measuringheads
1to6measuringheads
Blindzones
12
3
4
1 23
4
1to3measuringheads
ExactmeasurementofW,H,D1,D2
ExactmeasurementD1...Dn,max.,min.ComputedareaA
A
max.
min.n
TwistD2D1
HW
ExactmeasurementofW,H,D1,D2
ExactmeasurementD1...Dn,max.,min.ComputedareaA
A
max.
min.n
TwistD2D1
HW
5
6
5
6
SMR... Rotating GaugesFor round and non-round products such as squares,hexagons,flatsetc.Speciallydesignedforhighproductionspeed and short length.These gauges are based on thesamewellprovendesignastheoscillatingSMOsystems,howeverwithanovelfullycontactlesstransmissionsystemforbothpowerandsignals.Thankstothisuniqueconceptandthehighrotationalspeed,thefullprofile iscapturedwithin fractions of a second, allowing thus to minimizescrap production and to guarantee tighter tolerances.Twistand twistangledonotaffect themeasuring resultthankstoanintegrateddynamicregressionanalysisinthesoftwarepackage.Dependingonthemodel,thenumberofmeasurementaxes(scanners)canbe1,2or3.
Outstanding Advantages•Significantlyincreasedmeasuringratepersecond•Capturesatleast3profilesinlessthan1second•Alsocomputescrosssection(area)•Highreliabilitythankstothefullycontactless transmissionofpowerandsignals•Slimdesign
STATIC•OSCILLATINg•ROTATINg–THEBESTSOLUTIONFORANyAPPLICATION
X
X
X
d
4
Video
LaserscanThelaserbeamscansathighrates,typically1000/s(optionally2000/s)
Measureddimensiond(orthogonaltolaserdirection)
Outputsignaltoprocessor
Pulsecounter
ODAC®laserscannerswithlatestopticalandlasertechnologyaretheheartoftheSTEELMASTERgauges.Thefieldexperience,gained fromover65'000performingODAC® scannersandsystems, representsa solidbase fordesign refinementsandquality.ZUMBACHoffersmodelswithmeasuringfields from2upto500mm(.08upto19.68in.);biggermodelsuponrequest.
ReceiverEmitter
LaserbeamMeasuringfield
PrinterUSB
Remotescreens
Customernetw
ork(Ethernet)giantdisplayRS-422
FibreopticcabletoLPO
Alarms,startstatisticsetc.
STEELMASTERsystemsallowforoptimumconfigurationandlayoutofthemeasuringunit(s),processor,auxiliarydevices,networksandperipheralsforeachrollingmill.
LPO(LocalProcessingandOperationunit)
CPO(CentralProcessingandOperatorunit)Ascabinet,incl.TFTetc.oras19"rack
Blower/Filterunit(gE)
giantdisplaywith2,3or4lines
1–10remoteworkstations(PC's)forcommunicationoverETHERNETTCP/IP
Remoterepeaterscreenandkeyboard
Pyrometer
ETHERNETTCP/IP
Option:coolerorheater
max.20m(65ft.)
Fibreopticcable,max.500m(164ft.)
Upto4measuringunitsandLPO's
Outstanding Characteristics•Extremelyaccurate•Permanentlycalibrated•Highresolution•Highmeasuringrateofup to1000/s/axis(optionally: 2000/s/axis);6000/sfor6axes•Highimmunitytodirt•Totallyindependentofposition,vibration,temperatureofrolledproduct,lightintensityetc.
•Wellproven,extensivelifetime
SySTEMARCHITECTURE
THESENSORS
5
SMO... Oscillating GaugesForroundandnon-roundproducts(squares,hexagons,flats,rebaretc.)• Upto6measuringaxes• Seamless360°coverage• Noblindzones• Measurementindependentoftwist• Computesalsocrosssection• Oscillatingorstaticoperation
SMS... Static GaugesEspeciallysuitedforroundproducts• Upto6fixedaxes• Nomovingparts• Extremelycompact• Practicallynomaintenance• Extremelyfastmeasuringrate, shortmeasuringdistances• Mosteconomicversion
These units comprise the individual sensors (scanners), sealed from the harshmill environment bymeans of a uniqueprotectionsystem.Reliablefunctionisguaranteedthankstoanefficientairpurgingandcoolingsystemand,ifneeded,byawatercirculationsystem.Specialservicedoorsprovideeasyaccesstocleanthewindowsfromdust,howeverthisisrarelyneeded,thankstotheefficientairpurgingsystemwhichisstandardforallZumbachgauges.
SMR... Rotating GaugesForhigh-speedproductionsofroundandnon-roundproducts(squares,hexagons,flats,rebaretc.)•Upto3measuringaxes•High-speedseamless360ºcoverage•Upto100rpm(min.3fullprofilemeasurements/s)•Highreliability(fullycontactlesspowerandsignaltransmission)
•Rotatingorstaticorientableoperation
Alocalprocessingandoperationunit"LPO"isinstalledatmax.20m(65ft.)fromthemeasuringunit.Itpre-processesandfiltersthemeasuredvaluesinrealtime.Thedataissentviaonesinglefibreopticconnectiontothecentralcontrolandoperatingunit"CPO".Theheartofthe"CPO"isanindustrialembeddedPC,featuringallnecessaryinputsandoutputsfordisplayunits,printerorotherperipherals,Ethernet(TCP/IP)forcustomer(see"SystemArchitecture").
Anoptionalopticalpyrometercanbeusedtoprovidetheproducttemperature;thisinputisusedtocorrectthehotdimensionsintocoldcorrectedvaluesbeforebeingdisplayed,allowingthusrapidjudgementsbytheoperatorforanymilladjustmentsrequired.
STEELMASTERMEASURINgUNITS
STEELMASTERDATAACqUISITION,PROCESSINg,DISPLAy
6
Basic Software PackageSTEELMASTERAll functions for round products•Displayofmeanvalue,min.,max.,ovality•Hotand/orcoldvalues•Min./max.alarmlimits•Personalizedscreen•Sectionscreen•SplitscreenincaseofMULTIgAUgE•Trendgraph•Headandtailscraplengthindication•Productrecipe•Producttable/memory•Statistics•Printingreports•Maintenance,calibration
Sub-ModulesSTEELDATADatafiltering,preprocessing,computation
STEELGAUGESystemconfiguration
Thisisahighlydevelopedsoftware,provenandrefinedovermanyyears.Abasicpackageoffersallfunctionsneededforroundproducts.For all non-round products, such as squares, hexagons,flats,rebaraswellasforpolygonalshapedeviations(3-rollblocks),additionalsoftwaremodulesareavailable.Also for additional functions such as networkcommunication,dataarchiving,remoteworkstations,SPCstatisticsetc.,optionalmodulesarereadilyavailable.
Unique: There is only one hardware and software for all STEELMASTER versions, which can be upgraded any time.
Themaindatasuchasmeasuringrate,accuracy,measuringparametersandalloptionalupgradesarethesame.High flexibility allows for individual configuration of thescreens with section and trend displays, (numeric andgraphic), printing reports, statistics etc. as per specificneeds, and operating methods. Several programmableaccess levels andpasswords allow for optimumuseanddatasafety.
The state-of-the-art software allows an almost unlimitedselection for the graphical and numerical display of thenumerousparameters:
MULTIgAUgEdisplayof4measuringunits
PROFILESForsquares,hexagons,flats,specialprofiles
REMOTE STEELMASTERFornetworkingviaETHERNETTCP/IP,withupto10independentPCworkstations
STEELDATABASEForpostproductionviewingandarchiving(tobeinstalledonexternalPC's)
STEELHOSTStandardprotocolforETHERNETTCP/IP
SPCForSPCstatistics,configurable
REBARForrebarwithvariousgeometries
POLYGON / EPM / FPSEPMsoftwareforroundsandhexagons,forspecialasymmetricshapesandforthedeterminationofoutofroundconditions
EPM, the new Method and Software for Special Product GeometriesZUMBACHdevelopedanovelmethod,EPM(EnhancedProfileMeasurement,pat.pend.) forgeometrieswith irregularorasymmetric shapeaberrations (e.g.asymmetricoverfill orunderfill). Inparticular it is alsoable to captureand calculatepolygonalshapes,whichcanoccurincertainrollingprocessesoraftersubsequentpeeling/grindingoperations.Forany shape itwillmeasureathighaccuracynotonlymin.,max.andmeandiametersbutalso the trueout-of-rounddeviationRONtasdefinedbyISO/TS12181-1aswellastheinscribedcircleMICIandthecircumscribedcircleMCCI.AnoptionalmodulenamedFPS,especiallyfor3-rollblocks,is available for calculating accurate values formin.,max.,mean diameter and ovality, corresponding to the valueswhichwouldbefoundbymanual3-pointmicrometerscrews(ifbothreadingsarerelatedtoroomtemperature).ThisFPSmodule additionally calculates the "Touch" and "gap"diameterswhichareessentialfortheinitialrollsetting. 3-lobed 6-lobed Irregular Asymmetric
Software Options
STEELMASTERSOFTWARE
7
TheSTEELMASTERhardwareandsoftwarepermitstoconnectupto4measuringunitstothecentralPCandtoprocessanddisplayallsystemssimultaneously.Thisconfigurationhasprovedhighlysuccessfulovermanyyearsbecause:
• Itprovidesabetterandquickeroverviewandfullprocesstransparency• Itiseconomical•Substantiallysmallerinvestment
Theillustrationsshowsometypicalconfigurationsthathaveallproventheirefficiency.
Bar Mill
Rod Mill with Pre-/Post finishing
IntermediateRoughing
Rod Mill
Intermediateorprefinishing
Wirerodblock Postfinishing
Double Rod Mill Combined Bar/Rod Mill
Intermediate
Prefinishing
Finishing
3-rollblock
General Data of the Measuring UnitsMeasuringprinciple Laserscanningtangential(shadow)Measuringrate Upto1'000/s(optionally2'000/s)peraxis*Laser Laserdiodered,classIINumberofmeasuringaxes 1...6(dependinguponmodel)Resolution 0.001mm(.00004in.)Repeatability Typically±0.01mm*(.0004in.)Measuringtimes SMS: 1measurement(allaxessimultaneously)in1...20ms*(dependinguponmodel) SMO:1completeprofilein0.4...4s SMR:1completeprofilein0.1...0.3sOscillationangle Programmableupto180°**Dependinguponmodelandversion
Standard Models
Furthermodelsareavailable,dependingonproductandmeasurementrange1)Max.diameter=dependingontheguidingandvibrationMin.diameter=approx.1mm(.04in.)2)X=Numberofmeasuringaxes
Pleaseaskfordetailedliteratureaboutdataanddimensionsoftheindividualmodels.
•Technicalspecificationsaresubjecttochangewithoutnotice
MULTIgAUgECONFIgURATIONS
Model Measuringfield Max.productdiameter1)
mm Inches mm InchesSMS/SMO/SMR100-SX2) 100 4.00 80 3.2SMS/SMO/SMR160-SX2) 160 6.30 135 5.3SMS/SMO310-SX2) 310 12.20 280 20.0SMS/SMO550-SX2) 550 21.65 500 20.0SMS/SMOXXX-SX2) Specialrangesuponrequest
www.zumbach.com
Worldwide Zumbach Customer Service and Sales Offices
Switzerland(H.q.) Tel.+41(0)323560400,E-mail:[email protected] Tel.+54(0)1147010774,E-mail:[email protected] Tel.+32(0)24781688,E-mail:[email protected] Tel.+55(0)1938296000,E-mail:[email protected] Tel.+86(0)2154260443,E-mail:[email protected] Tel.+33(0)164244631,E-mail:[email protected] Tel.+49(0)22388099-0,E-mail:[email protected]
India Tel.+912026837949/50,E-mail:[email protected] Tel.+390332870102,E-mail:[email protected] Tel.+34936669361,E-mail:[email protected] Tel.+886226305530,E-mail:[email protected] Tel.+44(0)8707743301,E-mail:[email protected] Tel.+19142417080,E-mail:[email protected]
TheZUMBACHGroup •ZUMBACHAgencies
STEE.002.0002.EJUN.11