Shape Mediçao
- 1. Shape Technology Ltd GAUGING, MONITORING & MEASURING OPTO-ELECTRONIC SYSTEMS FOR THE STEEL & METAL INDUSTRIES
- 2. The Company Joint venture between Vidimon Shapemeter and Broner Engineering EES merged March 2003 IPL bought in May 2003 Approximately 50 employees Shape-Tech formed in 2001
- 3. The Products Process Measurement systems Available for over 20 years Flat products – Shapemeters, ISV Spray Bars, Edge Defect Detection Flat products – Width Gauge Long products – Profile measurement More than 700 systems worldwide
- 4. Reflex Gauge Air/Water Panel Workstation Pyrometer Manuals Training Course Gauge Head Operating Software
- 5. Reflex Gauge Designed to give complete on-line profile measurement of all standard and special sections Takes measurements in real-time and provides rolling mill staff with key measurement information Robust measurement gauge designed from Shape Technology's continued experience in harsh mill conditions What is Reflex ?
- 6. Principle of Operation Lasers project a continual stripe around the section CCD cameras 'grab' the image of each stripe Images are combined to provide a full profile
- 7. Principle of Operation Laser Stripe
- 8. Design Criteria Optimised camera mounting position provides guaranteed measurement of sharp internal angles and avoids self-shadowing
- 9. Design Criteria The effects of vibration are cancelled by mounting the optical system independently of the gauge body Every mill has inherent vibrations
- 10. Design Criteria 532 nm green laser Low Power (20 mW) "Eye Safe" Clear differential between laser light and infra-red light from the hot product Total laser safety is a must for all mills
- 11. Performance Figures 0.1 0.1 Full Profile Time (sec) 10 10 Measurement Rate (readings per sec) Four Four No. of Laser/Camera Modules ±0.45 ±0.2 Accuracy (mm) 450 mm 200 mm Max Product Size (mm) RX2 RX1 Model No.
- 12. Screen Display Screen is split into two main parts:
- 13. Dimension Display All dimensions displayed can be selected by user Trend indication gives immediate feedback to allow mill operators to adjust mill stands Weight per unit length measurement allows maximum output per melt
- 14. Product Display Accurate cross-section under on-line conditions Updated 10 times each second
- 15. Product Display Dynamic Real-time Template
- 16. Benefits Improvement in Product Quality Fast, accurate, real-time on-line measurements of all critical parameters Full Dimensional Control Indication of Roll Wear
- 17. Width Gauge Developments Width Gauge Developments
- 18. Width Measurement CCD Width Meters Stereoscopic Vision X & Y edge position measurement High measurement stability. Suitable for Hot Mill Environment Narrow down web field of view. Practical stand-off distance. Measurement accuracy Measurement Accuracy < +/- 0.8mm Width Control < +/- 8mm Down stream benefits Width Control using edger Width control at level 2
- 20. Block Diagram Serial/Ethernet Parallel Analog Junction Box Water Air Measurement Matrix Camera Roller Table Remote Operator Station Customer Equipment CCD2030 WIDTH GAUGE XXXXX XXXXX XXXXX XXXXX ees Main Electronics Cabinet CCD2030 Ethernet
- 21. CCD 2025/2030 Cameras Stereoscopic Cameras
- 22. The CCD 2025 Camera Stereoscopic Camera
- 23. The CCD 2030 Camera Stereoscopic Camera
- 24. Top side i nspection Gantry Application on the Mill
- 25. New Products
- 26. CCD 2040 Width Gauges
- 27. CCD 2040 Multi Function Width measurement Camber Measurement Crop shear control Thermal profile Flatness measurement
- 28. CCD 2040 – EES Width Gauge 4096 pixel camera resolution option and higher sensitivity extends the lower temperature range .
- 29. CCD 2040 – EES Width Gauge AC Circuit breakers LCD Flat Screen Monitor Win 2K LEP Real Time OS System Processor Pullout Keyboard Master AC Switch LV PSU’s for I/O etc Configurable Digital I/O Configurable Analogue I/O Camera interface unit with diagnostic features Network Connections
- 30. CCD 2040 – EES Width Gauge 8 isolated analogue outputs, 4 inputs. Up to 32 points of digital I/O HMI output scaling Hot and cold width Width deviation Centreline deviation Bar length Width Gauge Analogue & Digital I/O
- 31. CCD 2040 – EES Width Gauge CCD2040 Expansion Capability Up to 2 additional Width Measurements per cabinet Bar Camber Crop-shear Optimisation Thermal Profile Manifest Shape
- 32. Crop Shear Optimization & Control
- 33. Crop Shear Control System Two Parts to the system:- Bar End Shape Measurement & Cut Point Determination Shear Synchronisation & Control
- 34. Bar End Shape Acquisition Shape Camera Last RM Stand Square End Actual Profile Apparent Profile for Non-Stereoscopic Camera Stereoscopic Scan Compensates for “Ski-Tip” Lift
- 35. System Operation : Cut Offset Reference Bar End Shape Measurement & Cut Point Determination Centerline Reference Assumes no side-shift after end-shape scan Tip Reference Correct Optimized Offset independent of side-shift
- 36. Operator Display
- 37. Shear Control
- 38. Crop Shear System Tracking Camera Shear FM #1 Pinch Rolls Bar Speed Camera Shape Camera Last RM Stand Main Electronics Cabinet CCD3030 Blade Position Drive Pinch Roll Speed (tails) Speed Reference Optional Width HMD Back-up
- 39. Bar End Shape Acquisition Stereo Camera Single Camera
- 40. Crop Shear System Sensors Stereoscopic Width Gauge Camera Single CCD camera measurement
- 41. Crop Shear Control System Optimisation & Tracking Installation
- 42. Crop Shear Control System Alternative Sensors Close Range Hot Metal Detector Laser Speed Measurement
- 43. Benefits Potential savings through reduced yield losses are easily recognised. E.g. 2 million tonnes per annum Average Crop Yield Loss improvement 0.3% This exceeds a value of £300,000 per year Further savings by reducing crop failures of £150,000 per year Total £450,000
- 45. CCD 2040 – EES Width Gauge CCD2040 Roughing Mill Camber Measurement Second Stereoscopic Camera Additional Real-time PC & Camera Interface Camber Determination Algorithm
- 46. Camber Meassurement Camber Measurement Using 2 CCD Width Meters ~ 1M Plan View
- 48. CCD 2040 – Shape Measurement Laser module integrated into existing Stereoscopic Camera Single Camera for Centre-height Measurement Additional Real-time PC & Camera Interface Shape Determination Algorithm Shape Compensated Width Calculation
- 49. Width Correction Uncorrected width Steel with lateral shape Corrected Straight line width Steel with lateral shape Uncorrected width Corrected arc width
- 50. Multi-Point Shape Measurement Stereo Camera Laser Multiple spot laser projector Multiple laser spots positions detected by stereo camera Nth order poly-line curve fit through detected points for shape and corrected width calculation. Strip edge position detected by traditional width gauge edge detection
- 51. Shape Measurement Shapemeter / Width Gauge Combination
- 52. Thermal Profile
- 53. CCD 2040- EES Width Gauge CCD2040 Thermal Profile Measurement Thermo-profile calculation using exposure time & video level data. Thermo-profile HMI
- 54. System Architecture WinStrip MMI PC Real-time Operating System Width OPC Server Thermal OPC Server Width MMI Stereo CCD Camera Network communication PC
- 55. Thank you.
Editor's Notes
- #2: Title screen tells you who we are and what we do. CLICK: and this tells you who I am. CLICK