ࡱ> ܥhW egdvvv v ~ ~ ~ $       4 1        BEmX~  y|     v v       :v  ~  `^/ h v v v v    Advances in Infrared Line scanning for hot strip mill temperature measurement By Dr. Richard Salisbury Thermoteknix Systems Ltd., Mount Pleasant House, Mount Pleasant, Cambridge CB3 0RN, England Introduction Production of rolled strip products with uniform metallurgical and physical qualities requires consistent heating, rolling and processing. This can only be achieved if the temperature of the product is accurately known and maintained from the casting to the finishing sections. Until now temperature measurement on hot strip mills has had to rely largely on single point (spot) pyrometers. These are generally of a single or dual wavelength type. They are limited by their fixed position to the strip (usually mill centre line), large spot size and slow response. They do not give any indication of cross strip uniformity, cannot compensate for sideways strip movement and have no significant Operator feedback or quality value. Clearly they offer no information regarding edge effects or temperature related process variables. In some progressive plants, infrared line scanners have shown the advantages of real time cross strip temperature profiles. However, in nearly all cases this equipment has been used largely as an independent sensor to provide qualitative information and not as an integrated process measurement, control or formal quality tool. In 1996 Thermoteknix Systems Ltd. installed their Centurion high speed digital infrared line scanning temperature measurement system on the hot strip mill at China Steel Corporation, Taiwan (CSC) which encompasses the latest in digital infrared temperature measurement technology with advanced real time Windows software. This equipment has been integrated into the plants on line process measurement systems and is providing essential on line process and long term quality information. The WinStrip system is designed to satisfy three principal criteria: Improve manual/automatic on line process control to improve and maintain production standards. Provide documented quality assurance and long term traceability on a strip by strip basis. Interface data to temperature dependent plant functions and measurements. Purpose designed for the hot rolling mill, the system provides the following: On line real time measurement and display of cross and down strip temperature profiles and thermal maps on consoles distributed within different sections of the plant (e.g. Roughing mill pulpit, Finishing mill pulpit and Engineering Control Room Interface to Host Central Computer network to receive on line process data from the strip Automatic on line data archive and reference system for every strip On line alarm functions Direct outputs to external control systems (edge heaters, coolers) Off line post processing system Output on line strip temperatures to third party devices e.g. width, profile or thickness gauges System Overview Infrared Linescanner In order to provide reliable temperature measurements it is essential that the instrument has accurate absolute temperature measurement capabilities, a small spot size and high speed data processing to cope with the huge amount of data which is constantly generated. Centurion TS 50 digital infrared line scanner The Thermoteknix Centurion TS 50 is a high speed digital infrared line scanner of advanced design which sets new standards for high speed, accurate temperature monitoring in the process (Figure 1).  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\Pic1comp.tif" \* MERGEFORMAT \d  Figure  SEQ Figure \* ARABIC 1 Centurion TS 50 H digital infrared linescanner Based on state-of-the-art aerospace reflective optics, mounted on a high precision central spindle, the instrument combines all of the elements for non-contact, infrared linescanning, signal processing, data storage and communications in one integral unit. The Centurion is designed for long term performance and reliability in the harshest environments. An integral unit containing high precision rotating electro optics, parallel processing CPU electronics and heavy duty power supply, the Centurion is software controlled to provide a wide variety of integral on line analyses and data processing for hot strip, plate mill and annealing applications. Electro-Optics  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\Fg2comp.tif" \* MERGEFORMAT \d  Figure  SEQ Figure \* ARABIC 2 Centurion Optical path For the hot strip mill, a Centurion TS 50 H is used. This contains an Indium Gallium Arsenide infrared detector, spectrally filtered to 1.45 - 1.55 (, which in conjunction with its high precision control electronics produces an absolute temperature measurement accuracy of < 5 C over its range of 700 to 1400 C. For high sensitivity and resolution the Centurion has a precision spindle based rotating optic with all reflective optical path (Figure 2). Conventional focusing lenses are not used in the Centurion optical path. Instead, diamond turned, off axis parabolic mirrors are used to focus the energy from the strip onto the infrared detector. The advantages of this modern optical design are increased resolution, higher sensitivity and responsivity with a large (46 mm) aperture. This translates into a smaller spot size, more accurate temperature measurement and a faster scanning rate than previous generations of instrument.  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\pic3.tif" \* MERGEFORMAT \d  Figure  SEQ Figure \* ARABIC 3 Centurion Motor & Spindle In order to sustain long term high speed operation, a heavy duty brushless and frameless motor has been designed to withstand continuous high speed operation at speeds of 100 Hz. This is achieved by a combination of a high precision central spindle and large diameter bearings enclosed in labyrinthine seals mounted directly onto the spindle. The centre of mass of the rotating optical assembly is designed to pass through the centre of the bearings for immunity to vibration and minimal wear. By increasing the mass of the optical assembly the unit benefits significantly from a fly wheel effect to ensure consistent rotational and positional accuracy. (Figure 3). Processing In order to control the operation of the instrument and to process the mass of data generated at high speed, the Centurion has a powerful embedded CPU on a motherboard mounted in the rear compartment. This electronic board contains a 32 bit and a 16 bit parallel processing transputer with 4 MB RAM and EPROM. To cater for the high speed pre-processing required, an additional 32 bit transputer is used prior to transmission to the PC in the TS 50 and TS 100. The ease of increase of power and computational ability of the Centurion scanner design makes it an ideal intelligent scanner for on-line process applications. Its embedded processor unit is responsible for controlling the detector, motor, signal processing and signal transmission. Bi-directional digital transmission is made to the PC via RS 485 cable. A 1 MHz 14 bit Analogue to Digital converter in the Centurion produces 5500 temperature samples per line scan which are linearised by the processor according to the geometry and alignment of the scanner to produce 1120 linear measurements across the field of view. By default this is a 100 field of view, but the field of view is software selectable down to 15 and the 1120 sample linear frequency is maintained. Installation  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\pic4.tif" \* MERGEFORMAT \d  Figure  SEQ Figure \* ARABIC 4 Centurion steel enclosure A water cooled stainless steel enclosure is used to protect the scanner from the high radiation from the strip. (Figure 4). Two lasers are mounted adjacent to the front window to ensure accurate location above the strip. The enclosures are designed for ease of mounting and movement from one position on the line to another. In the China Steel installation three positions have been selected:- At the Roughing mill exit, the Finishing mill entrance and the Finishing mill exit. (Figure 5a). The strip temperatures vary between 700 - 1400C .  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\Fg5acomp.tif" \* MERGEFORMAT \d  Figure  SEQ Figure \* ARABIC 5a Centurion layout at China Steel Corporation, Taiwan  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\Fg5bcomp.tif" \* MERGEFORMAT \d  Figure 5b Screen Display from Finishing Mill Entry and Exit Centurions Accuracy In by an independent third party performance test of 2 Centurions it was found that both Centurions gave temperature measurements within 1 C of each other when viewing a NAMAS blackbody temperature reference for values between 700 and 1400 C. Furthermore, the greatest inaccuracy for either Centurion between blackbody absolute temperature over the same range and the Centurion measured value was 3 C. These tests were performed at 20 Hz and 50 Hz scanning speeds and repeated for targets placed at the centre and periphery of the field of view. Software The system is designed with a Client / Server central architecture. Live temperature data from the Centurion scanners and Process data are fed into the Server PC which acts as an I/O Manager and a series of Client (Viewer) PCs which access this data across the network. The software system can be regarded as having 2 main functions and any number of plant specific additions. These are: WinStrip Server for control of hardware components. It also collects, archives, integrates, interprets and distributes data collected by the scanners and other sensors and data sources. WinStrip Clients which are the operator stations for displaying and analysing live and archived data. The system can include a number of PCs linked together by a local area network but one of these plays a more central role. This Server PC' provides the interfaces and runs the software (WinStrip I/O Manager) for controlling and gathering data from other parts of the system and external sources. Outputs from the system include: Temperature data for thickness gauges 4-20mA analogue outputs Relay outputs Inputs include data from: The digital Centurion TS 50 H high speed scanners Velocity sensors Emergency stops A Primary Data Information (PDI) provider The Primary Data Information typically includes: Date and time and Centurion location Strip type and ID Strip width Emissivity or Alloy number Finishing temperature Furnace name Steel grade  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\Fg5ccomp.tif" \* MERGEFORMAT \d  Figure 5c WinStrip System Configuration The local area network is used to provide the Server PC with PDI information for the strips as they pass through the mills. This enables factors such as the individual strip emissivity at any position in the mill to be fed automatic into the WinStrip program. The Server PC collates the PDI information with the measurement data it gathers from the Centurions and other sensors. The Server PC then supplies this collated data through the network for viewing in real time using WinStrip Clients, which are running on the Roughing Mill PC, Finishing Mill PC and Engineering Control Room PCs. All strip data is automatically archived on to optical disk for later analysis using the WinStrip Clients. Centurion Software Technology A huge amount of data has to be processed as it arrives from the Centurions in order to display and analyse the thermal data in real time. The required performance has only been possible because of the integrated state-of-the-art parallel processing into the Centurion for data pre-processing and in the PC software technology.  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\Fg7comp.tif" \* MERGEFORMAT \d  Figure  SEQ Figure \* ARABIC 6 WinStrip Main screen layout The WinStrip Client is a 32-bit, multi-threaded application taking full advantage of the Microsoft Windows '95 operating system. The 32-bit technology provides performance gains which are further enhanced by the use of multi-threading. By devoting separate concurrent threads to different tasks within the software the computer can carry on working usefully on other threads when an individual thread is blocked waiting for some external event, such as new data arriving. The result is that the PC processor spends much less time idling and overall execution of the programme is very fast (Figure 7). Thermoteknix Systems Ltd. has been actively involved in Microsoft beta development programmes and has used this latest technology in the WinStrip software. The powerful, low-level, graphics functions provide state of the art real time performance for both information and temperature display. The networking architecture linking the various components in WinStrip provides a modular system with flexible options for upgrade and modification to suit hot rolling, plate mill and annealing applications. WinStrip Client Viewer Overview The WinStrip Viewer is used to display and analyse thermal measurements made by the Centurions and collected and processed by WinStrip Server. The strip data which is broadcast onto the network by WinStrip Server I/O Manager can be viewed in real time and simultaneously with saved data that has been automatically archived by WinStrip server. On-line data from multiple Centurion scanners can be shown in one Strip window on the screen and, in addition to this (or instead of it), several other Strip windows can be opened to display off-line data from previously archived strips at the same time. Each Client Viewer runs its own program independently on separate PCs on the network. Each one can be independently configured as best suits the location or process. For example, the Client PC in the Roughing Mill pulpit may be configured to show live Centurion scans at the Roughing Mill Exit and Finishing Mill Exit in Live modes. The Client PC in the Finishing Mill pulpit on the other hand may be configured to show live Centurion scans at the Finishing Mill Entry and Exit positions with side by side comparison to reference data. By using the factory wide network, Clients can be set up on PCs in remote locations outside the mill, such as in the engineering offices, where the process and production staff can view live and recalled data from product in production on the mill. The Operator stations typically see live line temperature data as the strip is passing the Centurions. As soon as the strip has passed the Centurion, WinStrip automatically processes the data to display a map of the whole strip from head to tail. This shows the changes in temperature which have occurred from start to finish as well as from side to side. Detection of Start and Finish as well as Near and Far edges are done automatically by the WinStrip software. This enables position relative (edge or mill centre) to be carried out. In theory, an unlimited number of viewer PC stations can be available, at different parts of the plant, each one seeing live/recalled data from any of the scanners, singly or in together. - Each PC occupies an Internet address and offer unmatched flexibility and performance, putting the live data where required and allowing analyses to be done which are appropriate to each location. Thermal data can be viewed as:  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\Fg8comp.tif" \* MERGEFORMAT \d  Figure  SEQ Figure \* ARABIC 7 WinStrip Thermal map A two-dimensional map with choice of palettes for representing temperatures by colours. (Figure 8).  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\Fg9comp.tif" \* MERGEFORMAT \d  Figure  SEQ Figure \* ARABIC 8 WinStrip 3D Live multi function display A three-dimensional map with thermal profile, down strip temperatures & selectable palettes (Fig 9) A temperatures map showing on line correction for sideways movement (sidewalk). (Figure 10) A variety of software tools provide: Down Strip Temperature Profiles for any given spot position across the strip Down Strip Differential Temperature Profiles between two points for any position across the strip. Temperature distributions Profile for any given area of the strip Area uniformity and defect analysis  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\Fg10comp.tif" \* MERGEFORMAT \d  Figure  SEQ Figure \* ARABIC 9 WinStrip edge detection with live uncorrected and corrected display Information from the host computer system is continually shown as PDI data together with the strip as it passes through the mill. The PDI strip width can be overlaid onto the dynamic thermal map to show the correlation between the measured strip width from a dedicated width gauge and the observed thermal width as determined by the WinStrip automatic edge detection system. Values for the alloy or emissivity are obtained via the PDI from previously entered look up tables or from external input. In order to correct for side to side movement of the strip on the mill, the thermal map as well as all measurements can be corrected for side walk (lateral movement from centre line) and displayed as corrected or uncorrected imagery. The whole image and all tools can be corrected for edge justification to compensate for sidewalk and facilitate down strip measurement and comparison between batches (Figure 10). The instantaneous sideways movement can be shown relative to the mill centre line and plotted as a function of length along the strip. Sidewalk from each scanner location can be compared simultaneously. Graphs can also be displayed for: The speed of the strip as it passes through the mill. The actual strip width deduced from the thermal data. Measured width from a third party gauge can also be input and read out along side. Data can be displayed In each Strip window from one or more Centurions at the same time. However, any Strip window can also be split into two or four separate panes showing different information about the strips. For example, you could have 2D Maps displayed in one pane, Strip Profiles in another, Edge Drop Profiles in a third and the Strip Speeds or side walk in the fourth. The arrangement of the data on the screen is completely within the Operators control (subject to the necessary Password access level). Data Storage Automatic on-line data storage of every strip is an important feature of the WInStrip system since it forms the basis for a long term Quality Assurance and Quality Management system. The WinStrip archive system ensures traceability for every strip which has been rolled. All on line measurements are made using the full 1120 linear temperature samples per scan at 50 Hz. A permanent record is kept on optical disk of the temperature and process data from every strip during its passage through the mill. The WinStrip Server is used to define the post processed resolution required for storage on every strip and the density of storage can be defined to suit user requirements. Each strip is saved with its scan profile/map thermal data at the specified resolution and PDI information, strip speed and width.  Figure 11 WinStrip Data File Manager A WinStrip File Manager displays lists of strip data in date, ID or other selectable order (e.g. furnace number) and a search and extract system allows any particular strip or set of strips to be identified and recalled. (Figure 11) Once recalled, full temperature analyses can be made using the software tools on the WinStrip Client Viewers. WinStrip Server and I/O Manager Overview The WinStrip Server and I/O Manager is the software hub of the Hot Strip Mill Linescan System. It runs on the central PC in which are installed the input / output interfaces to the other hardware components in the system. WinStrip I/O Manager allows the user to control the properties of these interfaces and to monitor their behaviour. For example, the WinStrip I/O Manager can be used to set and monitor alarm conditions on a range of analogue and digital inputs, as well as on the thermal data received from the Centurions. Mappings relating the values of a range of analogue and digital outputs to the values of the inputs can also be configured. As part of its underlying data handling, monitoring and diagnostic function, the WinStrip I/O Manager window displays a list of strips currently passing through the mills with their progress and status information. This provides the Operator with an immediate reference between the strips process, thermal and positional information which is invaluable particularly when there are more than one strip present on the mill at the same time or strips from different furnaces or grades. The WinStrip Server and I/O Manager is responsible for broadcasting the data it collects on to the network where it can be received by WinStrip Client Viewers for further analysis and display. After initial set up of the program, the WinStrip I/O Manager operates invisibly in the background without the need for user intervention. Process Benefits Following its successful installation and commissioning at China Steel Hot Strip Mill, Taiwan, the Centurion WinStrip Network system has provided a number of significant, direct, process diagnostics and benefits in addition to the archiving and Quality Assurance traceability of strip data. Abnormal de-scaling nozzle conditions were found to be rendering poor surface quality of the finished bar. This was found as a result of comparing the temperature profiles from the roughing mill exit and the finishing mill exit. The camber of the bar from the roughing mill exit and from the finishing mill exit was incorrect. By using the side to side movement measurements, the levelling of both mills was adjusted to improve the camber. Control of the edge temperatures was changed as a result of temperature profile measurement. New edge heaters will be fitted and WinStrip will be used to set up and to ensure that the correct parameters for the heaters are used. Whilst producing a low carbon steel at around 850C, the width gauge (unback lit) did not detect the edges correctly. WinStrip has provided exclusive and reliable width and side walk measurements. From the temperature profiles on low temperature steel, excessive cooling was detected on one side of the bar in the roughing mill and on the other side on the finishing mill. This was found to be due to abnormal conditions in the inter-stand cooling. Direct process adjustments are now made to compensate for this situation. Conclusion To improve, maintain and record the quality of strip production is at the heart of every modern steel plant. As a result of the co-operation between China Steel Corporation, Taiwan and Thermoteknix Systems Ltd., England a new system of temperature measurement and monitoring has been purpose developed which sets new standards for the hot strip and other rolling mill applications. Offering extremely accurate absolute temperature measurement, automatic data archive and strip by strip quality assurance measurements, the Centurion system can be integrated into the plant central computer network for on line process management and control. A significant number of process problems were detected and remedied using the WinStrip system including surface finish, camber, uniform heating and cooling and width measurement. The Thermoteknix WinStrip windows based software gives unrivalled ease of operator use as well as potential for data exchange with other equipment both on and off line. The system has been shown to offer highly accurate temperature measurement, reliability and clear financial benefit to the plant. Acknowledgement Thermoteknix acknowledge the help and support of the staff at China Steel Corporation, Taiwan throughout this project and for permission to reproduce the data shown. Centurion TS 50H WinStrip Infrared Line scanning system for Hot Strip  INCLUDEPICTURE "I:\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\hotsteel1.tif" \* MERGEFORMAT \d  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\hotroll.tif" \* MERGEFORMAT \d  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\scan&enc.tif" \* MERGEFORMAT \d  INCLUDEPICTURE "\\\\SERVER\\D\\2server\\Marketing\\ARTICLES\\Steel Times\\pictures\\Fg6comp.tif" \* MERGEFORMAT \d  Thermoteknix Systems Ltd. Mount Pleasant House, Mount Pleasant Cambridge CB3 0RN, England Tel. (+44) 1223 500777 Fax: (+44) 1223 500888 e-mail: r.salisbury@thermoteknix.com Captions to Figures Figure 1. Centurion TS 50 H digital infrared linescanner Figure 2. Centurion TS 50 H optical path (Cross section) Figure 3. Centurion TS 50 H precision spindle and motor Figure 4. Centurion TS 50 H water cooled steel enclosure Figure 5a. General layout at China Steel, Taiwan Figure 5b. WinStrip Screen Display from Finishing Mill Entry and Exit Centurions Figure 6. WinStrip main screen layout in Windows 95 Operating system Figure 7. WinStrip thermal map with individual palette control Figure 8. WinStrip three dimensional real time map Figure 9. WinStrip Profile and envelope display across strip Figure 10. WinStrip Edge justification of map and tool correction Figure 11. 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