аЯрЁБс>ўџ WYўџџџVџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџџьЅСq ПЏ5bjbjt+t+ &nAA—/џџџџџџ]””””PPPdddd8œ Ј4d_Ж№№ $є  2-P™23””“№333”†P dd”””” 3–3Щ %Л6P мРњywОddЙzр,ADVANCES IN THERMAL MONITORING TECHNIQUES FOR ROLLING MILLS Temperature measurement is a mandatory requirement for steel rolling process control. Spot pyrometers have been installed in many areas throughout the process to fulfil this role. The data provided by these instruments by their nature is very localised (typically to the mill centre) and does not give a true indication of the variations across the product that occur. Most temperature variations occur at the edges of product and due to sideways movement of product on the mill bed, these are areas that spot pyrometers cannot be used. Surface flaws and process irregularities are also missed due to the instruments’ slow response times. WinStripЎ is a high speed, high-resolution infrared scanning system that addresses these inaccuracies and provides additional benefits of accurate width measurement, real time QA and storage of process data. Implementing many years of infrared scanning experience coupled with pioneering technology, Thermoteknix have a truly unique measurement system offering stand alone instrumentation and turn key system process benefits. The Centurion TS50 digital scanner takes 1120 linear measurements per scan at a rate of 50 Hz. The field of view is configurable to adapt to each individual mill, independent of the instrument mounting height above the mill. The field of view is matched to different product types, from wire to strip and plate mills. Automatic software edge and product detection ensures that the maximum data is obtained in each application. Due to the huge volume of data which is collected, real time digital signal processing is undertaken inside the scanner and the processed data being digitally transmitted to the WinStripЎ server. WinStripЎ presents the live temperature to the operator in a variety of displays designed for immediate recognition of rolling problems or process variation. Product width is continuously measured through temperature threshold edge detection. With 1120 points per scan, product width can be measured with a resolution up to 1 mm, depending on scanning geometry. Visual and automated alarms are configured to detect abnormal process conditions with output alarming and data transfer in a variety of formats. A series of specially developed templates, based on temperature distribution and statistics at critical positions on the product, provide a continuously tracked document of product quality and proxy metallurgical characteristics. Encompassing a broad range of sensor inputs and data relating to each product, WinStripЎ provides a self contained system to archive and provide long term traceability. ON LINE REAL TIME TEMPERATURE MEASUREMENT There are over 1,000,000 spot temperatures recorded every 20 seconds as product passes each Centurion. Information is obtained immediately with the accuracy to generate thermal maps and establish physical dimensions and sideways movement as it travels through the mill. The thermal maps also gives the operator an indication of any ‘skidding’ or other roller related issues that affect the surface of the product. Figure 1. Typical WinStripЎ display for temperature profiling ON LINE ALARM FUNCTIONS (BLOCKED OR BLOWN COOLING NOZZLE DETECTION) WinStripЎ is a real time monitoring process. Alarms are triggered as soon as a potential problem is detected. An example is blocked cooling nozzles that are quickly detected as they result in a ‘hot’ trace being present along the product length. Too small and localised for a spot pyrometer to detect, WinStripЎ detects the problem the moment it occurs. Blown nozzles can also be detected by the same means where overcooling occurs. The sooner such faults are detected and remedial action taken, the less scrap is produced and less is the effect on mill yield. WinStripЎ has proven to offer very quick return on investments on just these alarm facilities alone. Alarm monitoring continues even when product data is post processed off line. MEASUREMENTS RELATIVE TO THE STRIP POSITION – NOT THE MILL Spot pyrometers historically are mounted over the centre of the mill bed. Their position is fixed relative to the bed. When the hot product travels through the mill, material moves from side to side. The spot pyrometer will be measuring the temperature of the material which is at the mill centre, not the product centre. The severity of this error depends on the extent of sideways movement. WinStripЎ software allows the system to take ‘spot profile’ temperatures along the product length that are true measurements to the product position. Their output lends itself directly to control of cooling sprays or edge heating devices. STRIP OR PLATE ‘SIDEWALK’ MEASUREMENTS ALONG THE MILL As highlighted in previous sections, the high number of measurements allows the lateral movement of the product to be continuously measured. Thermal maps can have the sidewalk graphically displayed for easy operator recognition. DISPLAY OF CROSS AND DOWN STRIP TEMPERATURE PROFILES Temperature profiles can be taken along the product length and laterally across the product. The measurements are taken at the same position on all successive products so comparisons and standards are established. Because of the high resolution of the Centurion, measurements can be within a few millimetres of the product edges and this position is maintained from head to tail, impossible to achieve with conventional methods. THERMAL MAPS ON CONSOLES DISTRIBUTED WITHIN DIFFERENT SECTIONS OF THE PLANT WinStripЎ installations are based on providing the complete line with effective measurement tools. This is possible due to the client server configuration shown below. This allows data to be seen and evaluated at different stages along the mill. Figure 2. Typical WinStrip configuration. AUTOMATIC ON LINE DATA ARCHIVE AND REFERENCE SYSTEM FOR EVERY STRIP WinStripЎ can accept multiple sources of input data relating to product ID. Because product passes continuously down the mill, measurements are taken at different times. WinStripЎ organises all the data in its mass storage facility ensuring it is all retained together in a single file, referenced to its product ID, and indexed to the correct timings on the mill. When recalling product information, it’s presented in a single, integrated, clear fashion. All of the thermal and input data that is collected on a product is stored. This ensures full traceability in a format that’s both easy to access and interpret OFF LINE POST PROCESSING SYSTEM Real time processing provides immediate feedback on performance. However, in order to understand correlation of process data with metallurgical and physical properties, the data must be analysed off line. WinStripЎ mass storage integrates all process data under the product ID code providing a simple retrieval system. A single key recall button as well as search strings for group identification of products by furnace number, steel grade, target temperature etc. allow direct comparison as well as re-analysis with live or archived data. By treating all historical data as if it were live data, the same measurements are applied and the user interface kept clean and simple. Parallel processing within the Centurion ensures WinStripЎ continues to collect, process and archive live data from different parts of the mill whilst this occurs. Centurion offers wide suitability for many products A range of high performance infrared detectors are used in the Centurion for maximum sensitivity allowing temperature ranges between 100~1600(C. The unique design typically provides a repeatable absolute temperature accuracy within Б 5 (C. For optimum performance, which is independent of the high ambient temperatures and vibrations that occur in all mills, the Centurion has a precision spindle based rotating optic with all reflective optical path. Diamond turned parabolic mirrors are used to focus the energy onto the detector. The advantages of this modern optical design are: Increased resolution Higher sensitivity with the large aperture Smaller spot measurement size Accurate temperature measurement Faster scanning rate Minimal maintenance An independent third party performance test of 2 Centurions found that both units gave temperature measurements within Б 1 АC of each other when viewing a NAMAS blackbody temperature reference for values between 700~1400 АC. Figure 3. Centurion high speed digital infrared scanner INTERFACE TO HOST CENTRAL COMPUTER NETWORK TO RECEIVE ON LINE PROCESS DATA WinStripЎ installation allows a great deal of useful data to be collected, stored, analysed and retrieved. To ensure full plant integration, WinStripЎ communicates with the central computer network using TCP/IP protocol. The integration ensures that the product is allocated correct reference numbers and other additional data, such as the furnace number referenced to the respective WinStripЎ data files. DIRECT OUTPUTS TO EXTERNAL CONTROL SYSTEMS (EDGE HEATERS, COOLERS) The high resolution of WinStripЎ gives accurate temperature of the complete product down to a very fine spatial resolution. This level of accuracy is exploited to its full potential when looking for temperature deviations such as areas that are too hot or cold at the very edges of product. Real time information is used to control external processes, either by processed data output on the TCP/IP link or by serial or analogue signals. If the edges are cooling too rapidly, WinStripЎ has a built in facility to switch external equipment such as edge heaters for rapid response and process correction. Figure 4. WinStripЎ high resolution thermal map (note the resolution at the edges). OUTPUT DATA TO THIRD PARTY DEVICES E.G. WIDTH, PROFILE, THICKNESS GAUGES Most thickness and shape gauges rely on ‘hot’ measurements that are extrapolated to the finished material temperatures. Accordingly, absolute temperatures fed into those systems have a direct effect on the resulting accuracy of the width, shape and thickness values. This is of particular importance where edge drop and shear affect yields. With 1120 measurements across the product, WinStripЎ provides essential data that is needed for accurate gauge performance. ABILITY TO PRE-SET QA MEASUREMENT PROTOCOLS AND APPLY THEM STRIPS Repeatability and traceability are key elements to any successful quality system. WinStripЎ delivers these with built in QA procedures. A system has been developed based upon specific, pre-designed templates. These analysis templates provide a detailed proxy to metallurgy and physical properties. By applying this to live product and transmitting to the host system, the results allow on-line process changes to conform to a standard. Post process application on archived products allows quality standards to be defined for Plant and Customers. This unique QA management tool can be localised to particularly critical parts of the product, such as head, tail, or edges, providing reproducible results and identifying optimum material yield levels. ADVANCES IN THERMAL MONITORING TECHNIQUES FOR ROLLING MILLS. WinStripЎ provides a new approach to temperature and width measurements within an integrated QA package. Utilising the latest in high resolution digital cameras, its client-server Windows"! architecture displays, measures and processes data for a wide range of metal products between 100~1500 (C. Integrating measurements from a variety of sensors throughout the process, with its own high resolution temperature and width measurements, WinStripЎ identifies many critical surface and thermally related anomalies during rolling. Over 50,000 linear measurements per second identify edge and edge drop related effects. On and off line software tools allow Operators and engineers to compare and measure performance in accordance with customer and process codes. WinStripЎ contains a Quality Assurance system based on a proxy metallurgical process model. It provides traceability and standards performance to suit customer and plant requirements. 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