轧辊辊印检测装置 RollMarkDetector.docx

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