轧辊辊印检测装置 RollMarkDetector.docx
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轧辊辊印检测装置 RollMarkDetector.docx
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轧辊辊印检测装置RollMarkDetector
FRPEuropeTechnology
REPORTCI-01/03
SISROLLMARKDETECTORTESTIN
SABIÑÁNIGO
Authors:
S.SánchezVilluendas
C.GarcíaCordovilla
V.MartínSáenzdeMiera
Date:
MarchCopy:
10
ALCOAPROPRIETARY
ThecontentsofthisdocumentcontainPROPRIETARYinformation.
Thepersonreceivingsuchinformationisfullyresponsibleforitssafekeeping.
REPORTCI-01/03
TITLE:
SISROLLMARKDETECTORTESTINSABIÑANIGO.
PURPOSE:
ExplorethepossibilitiesofanopticaldetectorofperiodicfeaturesinarollmillmanufacturedbySIS.
SCOPE:
InstallationandoperationofatestunitinTrébolmillfor6months.
CONCLUSIONS:
Thedetectoriscapableofdetectingtherollmarksonthemill,beingaveryusefulandcosteffectivetoolfortheplant.Itisrecommendedtofurtherexplorethepossibilityofinstallingasysteminthe1400linethatexperiencesthehigherrateofmarks.
Specialcareshouldbetakentoavoidtheproblemsencounteredduringthetestintheproductionunitandguaranteeproperserviceinthefuture.
Thesystemishighlyrecommendabletofoilplants.
AUTHORS:
S.SánchezVilluendas
C.GarcíaCordovilla
V.MartínSáenzdeMiera
DISTRIBUTIONLIST
Copynº
FRPEVice-presidentOperations:
Mr.Wieser1
ALCOAALICANTE:
Mr.DePáramo2
Mr.GiménezCandela3
ALCOASABIÑANIGO:
Mr.Ferrer4
Mr.Parlange5
Mr.Sánchez6
ATCPITTSBURG:
Mr.Adomaitis7
Mr.Koch8
FRPET:
Mrs.GarcíaCordovilla9
Mr.Martín10
Mr.J.L.Gazapo11
Mr.J.Terol12
Library0
1.INTRODUCTION
SinceSeptember2000,asurfacemonitoringsystemtodetectonlinetheoccurrenceofrollmarksinthemill,providedbySISGmbHhasbeeninoperationinSabiñánigointhe1700'Trébol'mill.Theobjectiveofthetestwastotestthecapabilityofthesystemtoperformitsintendedrole,providingatooltoeliminatefullcoillosesandeliminatetimeconsumingstopsofthemill,thusimprovingrecoveryandproductivity.
ThesuppliercontactedFRPEtoofferthepossibilityofinstallingatestarrangementinafoilmillonleaseduringseveralmonths.AfterdiscussionwithSabiñánigo,itwasdecidedthatitcouldbeaveryusefultechnologyworthpursuing,placinganordertotestthesystem.ItwasdecidedthatitshouldbeinstalledintheTrébolmill,astheimpactofsinglefullcoillossesisbiggerinthismill.Sincetheinstallation,Sabiñánigopersonnelhasbeeninstrumentalinachievingthemostbenefitoutofit,fromexecutionoftheadaptationtothemilltodailycareoftheunitandthoroughstudyofeverysingledetection.
2.DESCRIPTIONOFTHESYSTEM
StruckInnovativeSystemsGmbH(SIS)developedRollmaX(incollaborationwithEurofoil)aspecializedanddedicatedautomatedwebinspectionsystemwiththetasktodetectonlyrepetitivedefects(likerollmarks).Itoperatesdirectlyattheexitsideoftherollingmillwhilerolling,andisclaimedtodetectrollmarksproducedinthecurrentrollingpass.Itallowsimmediatereactionoftheoperatorsinordertostoprollingandchangecriticalworkrollsandhenceitresultsinconsiderablescrapreductionandimprovementofproductivityandquality.
Thesystemconsistsofadetectionheadthatincorporatesalasersourceilluminatingtheproductsurface.Aphotosensitivesensorelementreceivesareflectionfromtheproductsurfaceandgeneratesananalogsignalthatcorrelatestothesurfacestructureoftheinspectedrolledproduct.Theanaloguesensorsignaliscontinuouslydigitized,analyzedandclassified.Itdoesnotcovertheentirewebwidthatonce;thesensorheadscanscontinuouslyacrossthefoilwhileexaminingthesurfacethroughanarrowinspectionwindow.Theheadstopstoscaneachparticularpositionforapredeterminednumberofrollturns,takingthusatimecloseto10minutestoscanthecompletewidth.Itmeasuressurfaceanomaliesinreferencetotheactualsurfacebackground(roughness)ofthestrip.Thegeneratedsurfacesignalislinkedwithafrequencysignalfromtherollencoder,thusallowingonlydetectionofrollmarksproducedinthecurrentpass(thismakesthesystemsimplerandlowercost).Onceithascompletedascanofthesurface,theheadgoesbacktothepositionswhereanomalieshavebeendetectedtomakeamoredetailedmeasurement.Surfacedefectsarereportedtoandtreatedbyacomputer,whichactsasoperatorsconsole(graphicaluserinterface).Wheneveramarkisdetected,itappearsinthescreenshowingitspositionand"signalintensity".Thesystemonlyprovidesareferenceofthedifferenceonreflectedlightintensityfromgeneralbackground;itdoesnotdetectdirectlysizeorshapeofdefects,soonedifficultyistoreliablydistinguishbetweennon-acceptableandacceptablemarksbasedonintensityofsignal.Thusacalibrationstepisnecessarybeforeoperationinaroutineproductionbasis.
Thesystemisclaimedtooperatecontinuouslyatstandardfoilrollingspeedswithoutdecreaseofdetectionsensitivity,uptoatemperatureof80°C,in“dense”kerosenevapour(acontinuoussupplyofcompressedairavoidsmillfumestoenterintothesensorhead).Thesystemcan“survive”typicalmillfireswithoutdamage.Typical“millevents”likefoilbreaks(evenatgauge>0.1mm),cleaning,threading,etc.donotaffectthesystem.
FoilWidth:
1700mmmax.
FoilGauge:
6.35µmto100µmtypical(non-relevant)
Rollingspeed:
200m/min...1300m/min
Cross-webScanTime:
ca.5min/mat1000m/minrollingspeed.
CrosswebSpatialresolution:
3mmtypical
DefectClasses:
Repetitivesurfaceimprints(Periodicspotrollmarks).
Repetitiverollholes(piercing)(Optional,needsanadditionaldetectorontheothersideoftheweb).
Onrequestthesystemcanbeextendedto:
-Chattermarks
-Pinheads(elevations)
-Herringbonepatterns
DefectSize:
min0.2mmdependingonsurfaceproperties
EnvironmentalTemperature:
<70°C(Sensorhead)
<50°C(Electronicchassis)
Atmosphere:
Rollingoilvaporandfluid
Specials:
Resistanceagainst“short”millfires.
Resistanceagainsttypicalmillprocedures
(Cleaning,foilbreak,threadingetc.)
PowerSupply:
210-240V/50Hz,SinglePhase,<1kW
CleanPower(suitedforComputer)
AirSupply:
5barMin,7barmax,valveadjustable
Cleanedbymicrofilter,<40°Ctemperature
Thetestsysteminstalleddiffersfromastandardoneinitsrobustnessandreliability.Itisfittedattheexitsideofthemill,sothattheheadispositionedclosetothebridlerollandthewholefixturemoveswithitforthreadingandcleaningoperations.Whileapermanentsysteminterfaceshouldbeinstalledintheoperatorcabin,thetestsystemPCwasinstalledclosetothemillatanavailablespaceonthemotorsside.Thetestsystemisdesignedtoworkonlywhenexitgaugeislowerthan65μm.Thelaserheadisadjustedtobealwaysat4mmofthefoilsurfacewiththeexitbridlerollinitslowestposition(wrapanglewithflatnessbar34º).Thetestsystemisalsolimitedtocover1380mmofthewidthofthestrip(seefiguresintheattachment).
Thecostofastandardunitiscloseto100k$.Incomparisonwithgeneral-purposesurfaceinspectionsystems,itisquitecompetitiveinprice.Thisisduetotheveryfocusedapproachtorepetitivedefectsthatextremelysimplifiesthesystem,whileavoidingthemostdamagingdefectstooperationofafoilmill.
Currentlythereisonlyonecompletesysteminstalledintheworld,inEurofoil,withtwosensorheads(topandbottomoftheweb),soitcandetectifthemarkperforatesthewebornot.ThetestsystemhasalsobeentriedinVAW(Irurzun,Spain)anditseemsitisgoingtobeinstalledinLine1atGrevenbroich.ThecostofthetestfromSeptembertoFebruaryisof22500DM.
3.IMPACTOFTHESYSTEMONPLANTPERFORMANCE
ThedatafromSabiñánigoonrollmarksincidentsin1999are:
Mill
Totalscrap
(kg)
Deviated
(kg)
Scrapped
(kg)
Trébol
33800
37909
14846
Altea+Zinnia
36381
53170
9796
Andatotalof1221kgfromcustomersclaims.
Reducingthesefiguresin90%wouldmakeanannualcostreductionof59.5k$fortheplantjustbasedonscrapcosts.Someotherbenefitsnotquantifiedwouldbetheimprovementofthereliabilityofproduction,withimpactonproductivityandservice.
4.SYSTEMPERFORMANCE
Sincetheinstallationoftheunit,ithasdemonstrateditsabilitytodetectrollmarksevenwithoutanassociatedhole.CurrentlySabiñánigorejectionlimitbasedonsizeis0.2mmforperforatingmarks.Sincethebeginningofthetest,workstartedtodeterminetheintensitylevelthresholdtostopthemill.Afteronemonthofoperation,itwasdeterminedthemillshouldstopinpackpasswheneverthesignalintensitywerebiggerthan150points,oratanymarkduringsplitpass.Thereasonforthislastprecautionwastoallowstudyofthemarkanditspossibilitiesofgrowthinthenextpass(alsoitwouldbeundetectedbythesysteminthenextpass).
Thesystemisabletodetectcloseto90%oftherejectablemarks.Thereisapossibility(lowerthan0.5%)ofreportinganon-rejectableoneasrejectable.Duringitsoperationinthemill,thedetectorhasidentified34rollmarks.Ofthese,onlythreewerecriticalones.Another3non-criticalmarkshavepassedundetected,butnocriticalmarkhasbeenundetected.
Currentthresholdofdetectionisseton20scalepoints(arbitraryunits).Between20and150pointsmostoftherollmarksproducedhavebeendetectedandnorejectablemarkhasbeenundetected.Anumberofcoilshavebeensavedfrombeingscrapp
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