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Shape Technology Ltd GAUGING, MONITORING & MEASURING OPTO-ELECTRONIC SYSTEMS FOR THE STEEL & METAL INDUSTRIES
The Company <ul><li>Joint venture between Vidimon  Shapemeter and Broner Engineering   </li></ul><ul><li>EES merged March ...
The Products <ul><li>Process Measurement systems </li></ul><ul><li>Available for over 20 years </li></ul><ul><li>Flat prod...
Reflex Gauge Air/Water Panel Workstation Pyrometer Manuals Training Course Gauge Head Operating Software
Reflex Gauge <ul><li>Designed to give complete on-line profile measurement of all standard and special sections </li></ul>...
Principle of Operation <ul><li>Lasers project a  continual stripe around  the section </li></ul><ul><li>CCD cameras  'grab...
Principle of Operation Laser Stripe
Design Criteria Optimised camera mounting position provides guaranteed measurement of sharp internal angles and avoids sel...
Design Criteria The effects of vibration are cancelled by mounting the optical system independently of the gauge body Ever...
Design Criteria <ul><li>532 nm green  laser </li></ul><ul><li>Low Power  (20 mW) </li></ul><ul><li>&quot;Eye Safe&quot; </...
Performance Figures 0.1 0.1 Full Profile Time (sec) 10 10 Measurement Rate (readings per sec) Four Four No. of Laser/Camer...
Screen Display Screen is split into two main parts:
Dimension Display <ul><li>All dimensions displayed  can be selected by user </li></ul><ul><li>Trend indication gives  imme...
Product Display <ul><li>Accurate  cross-section  under  on-line   conditions </li></ul><ul><li>Updated 10  times each  sec...
Product Display <ul><li>Dynamic </li></ul><ul><li>Real-time </li></ul><ul><li>Template </li></ul>
Benefits Improvement in Product Quality <ul><li>Fast, accurate, real-time on-line measurements of all  critical parameters...
Width Gauge Developments Width Gauge Developments
Width Measurement <ul><li>CCD Width Meters </li></ul><ul><li>Stereoscopic Vision </li></ul><ul><ul><li>X & Y edge position...
Typical Installation
Block Diagram Serial/Ethernet Parallel Analog Junction Box Water Air Measurement Matrix Camera Roller Table Remote Operato...
CCD 2025/2030 Cameras Stereoscopic Cameras
The CCD 2025 Camera Stereoscopic Camera
The CCD 2030 Camera Stereoscopic Camera
Top side i nspection Gantry Application on the Mill
New Products
CCD 2040 Width Gauges
CCD 2040 Multi Function <ul><li>Width measurement </li></ul><ul><ul><li>Camber Measurement </li></ul></ul><ul><ul><ul><li>...
CCD 2040 – EES Width Gauge <ul><li>4096 pixel camera resolution option and higher sensitivity extends the lower temperatur...
CCD 2040 – EES Width Gauge AC Circuit breakers LCD Flat Screen Monitor Win 2K LEP Real Time OS System Processor Pullout Ke...
CCD 2040 – EES Width Gauge <ul><li>8 isolated analogue outputs, 4 inputs. </li></ul><ul><li>Up to 32 points of digital I/O...
CCD 2040 – EES Width Gauge <ul><li>CCD2040 Expansion Capability </li></ul><ul><li>Up to 2 additional Width Measurements pe...
Crop Shear Optimization & Control
Crop Shear Control System <ul><li>Two Parts to the system:- </li></ul><ul><ul><li>Bar End Shape Measurement & Cut Point De...
Bar End Shape Acquisition Shape Camera Last RM Stand Square End Actual Profile Apparent Profile for Non-Stereoscopic Camer...
System Operation : Cut Offset Reference <ul><ul><li>Bar End Shape Measurement & Cut Point Determination </li></ul></ul><ul...
Operator Display
Shear Control
Crop Shear System Tracking Camera Shear FM #1 Pinch Rolls Bar Speed Camera Shape Camera Last RM Stand Main Electronics Cab...
Bar End Shape Acquisition Stereo Camera Single Camera
Crop Shear System Sensors <ul><li>Stereoscopic Width Gauge Camera </li></ul><ul><li>Single CCD camera measurement </li></ul>
Crop Shear Control System Optimisation & Tracking Installation
Crop Shear Control System Alternative Sensors <ul><li>Close Range Hot Metal Detector </li></ul><ul><li>Laser Speed Measure...
Benefits <ul><li>Potential savings through reduced yield losses are easily recognised.  E.g. </li></ul><ul><ul><li>2 milli...
Camber Measurement
CCD 2040 – EES Width Gauge <ul><li>CCD2040 Roughing Mill Camber Measurement  </li></ul><ul><li>Second Stereoscopic Camera ...
Camber Meassurement Camber Measurement  Using 2 CCD Width Meters ~ 1M Plan View
Shape Measurement
CCD 2040 – Shape Measurement <ul><li>Laser module integrated into existing Stereoscopic Camera </li></ul><ul><li>Single Ca...
Width Correction Uncorrected width Steel with lateral shape Corrected Straight line width Steel with lateral shape Uncorre...
Multi-Point Shape Measurement Stereo Camera Laser Multiple spot laser projector Multiple laser spots positions detected by...
Shape Measurement Shapemeter / Width Gauge Combination
Thermal Profile
CCD 2040- EES Width Gauge <ul><li>CCD2040 Thermal Profile Measurement </li></ul><ul><li>Thermo-profile calculation using e...
System Architecture WinStrip MMI PC Real-time Operating System Width OPC Server Thermal OPC Server Width MMI Stereo CCD Ca...
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Shape Mediçao

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Shape Mediçao

  1. 1. Shape Technology Ltd GAUGING, MONITORING & MEASURING OPTO-ELECTRONIC SYSTEMS FOR THE STEEL & METAL INDUSTRIES
  2. 2. The Company <ul><li>Joint venture between Vidimon Shapemeter and Broner Engineering </li></ul><ul><li>EES merged March 2003 </li></ul><ul><li>IPL bought in May 2003 </li></ul><ul><li>Approximately 50 employees </li></ul><ul><li>Shape-Tech formed in 2001 </li></ul>
  3. 3. The Products <ul><li>Process Measurement systems </li></ul><ul><li>Available for over 20 years </li></ul><ul><li>Flat products – Shapemeters, ISV Spray Bars, Edge Defect Detection </li></ul><ul><li>Flat products – Width Gauge </li></ul><ul><li>Long products – Profile measurement </li></ul><ul><li>More than 700 systems worldwide </li></ul>
  4. 4. Reflex Gauge Air/Water Panel Workstation Pyrometer Manuals Training Course Gauge Head Operating Software
  5. 5. Reflex Gauge <ul><li>Designed to give complete on-line profile measurement of all standard and special sections </li></ul><ul><li>Takes measurements in real-time and provides rolling mill staff with key measurement information </li></ul><ul><li>Robust measurement gauge designed from Shape Technology's continued experience in harsh mill conditions </li></ul>What is Reflex ?
  6. 6. Principle of Operation <ul><li>Lasers project a continual stripe around the section </li></ul><ul><li>CCD cameras 'grab' the image of each stripe </li></ul><ul><li>Images are combined to provide a full profile </li></ul>
  7. 7. Principle of Operation Laser Stripe
  8. 8. Design Criteria Optimised camera mounting position provides guaranteed measurement of sharp internal angles and avoids self-shadowing
  9. 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. 10. Design Criteria <ul><li>532 nm green laser </li></ul><ul><li>Low Power (20 mW) </li></ul><ul><li>&quot;Eye Safe&quot; </li></ul>Clear differential between laser light and infra-red light from the hot product Total laser safety is a must for all mills
  11. 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. 12. Screen Display Screen is split into two main parts:
  13. 13. Dimension Display <ul><li>All dimensions displayed can be selected by user </li></ul><ul><li>Trend indication gives immediate feedback to allow mill operators to adjust mill stands </li></ul><ul><li>Weight per unit length measurement allows maximum output per melt </li></ul>
  14. 14. Product Display <ul><li>Accurate cross-section under on-line conditions </li></ul><ul><li>Updated 10 times each second </li></ul>
  15. 15. Product Display <ul><li>Dynamic </li></ul><ul><li>Real-time </li></ul><ul><li>Template </li></ul>
  16. 16. Benefits Improvement in Product Quality <ul><li>Fast, accurate, real-time on-line measurements of all critical parameters </li></ul><ul><li>Full Dimensional Control </li></ul><ul><li>Indication of Roll Wear </li></ul>
  17. 17. Width Gauge Developments Width Gauge Developments
  18. 18. Width Measurement <ul><li>CCD Width Meters </li></ul><ul><li>Stereoscopic Vision </li></ul><ul><ul><li>X & Y edge position measurement </li></ul></ul><ul><ul><li>High measurement stability. </li></ul></ul><ul><li>Suitable for Hot Mill Environment </li></ul><ul><ul><li>Narrow down web field of view. </li></ul></ul><ul><ul><li>Practical stand-off distance. </li></ul></ul><ul><li>Measurement accuracy </li></ul><ul><ul><li>Measurement Accuracy < +/- 0.8mm </li></ul></ul><ul><ul><li>Width Control < +/- 8mm </li></ul></ul><ul><li>Down stream benefits </li></ul><ul><ul><li>Width Control using edger </li></ul></ul><ul><ul><li>Width control at level 2 </li></ul></ul>
  19. 19. Typical Installation
  20. 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. 21. CCD 2025/2030 Cameras Stereoscopic Cameras
  22. 22. The CCD 2025 Camera Stereoscopic Camera
  23. 23. The CCD 2030 Camera Stereoscopic Camera
  24. 24. Top side i nspection Gantry Application on the Mill
  25. 25. New Products
  26. 26. CCD 2040 Width Gauges
  27. 27. CCD 2040 Multi Function <ul><li>Width measurement </li></ul><ul><ul><li>Camber Measurement </li></ul></ul><ul><ul><ul><li>Crop shear control </li></ul></ul></ul><ul><ul><ul><ul><li>Thermal profile </li></ul></ul></ul></ul><ul><ul><ul><ul><ul><li>Flatness measurement </li></ul></ul></ul></ul></ul>
  28. 28. CCD 2040 – EES Width Gauge <ul><li>4096 pixel camera resolution option and higher sensitivity extends the lower temperature range . </li></ul>
  29. 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. 30. CCD 2040 – EES Width Gauge <ul><li>8 isolated analogue outputs, 4 inputs. </li></ul><ul><li>Up to 32 points of digital I/O </li></ul><ul><li>HMI output scaling </li></ul><ul><ul><li>Hot and cold width </li></ul></ul><ul><ul><li>Width deviation </li></ul></ul><ul><ul><li>Centreline deviation </li></ul></ul><ul><ul><li>Bar length </li></ul></ul>Width Gauge Analogue & Digital I/O
  31. 31. CCD 2040 – EES Width Gauge <ul><li>CCD2040 Expansion Capability </li></ul><ul><li>Up to 2 additional Width Measurements per cabinet </li></ul><ul><li>Bar Camber </li></ul><ul><li>Crop-shear Optimisation </li></ul><ul><li>Thermal Profile </li></ul><ul><li>Manifest Shape </li></ul>
  32. 32. Crop Shear Optimization & Control
  33. 33. Crop Shear Control System <ul><li>Two Parts to the system:- </li></ul><ul><ul><li>Bar End Shape Measurement & Cut Point Determination </li></ul></ul><ul><ul><li>Shear Synchronisation & Control </li></ul></ul>
  34. 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. 35. System Operation : Cut Offset Reference <ul><ul><li>Bar End Shape Measurement & Cut Point Determination </li></ul></ul><ul><li>Centerline Reference </li></ul><ul><ul><li>Assumes no side-shift after end-shape scan </li></ul></ul><ul><li>Tip Reference </li></ul><ul><ul><li>Correct Optimized Offset independent of side-shift </li></ul></ul>
  36. 36. Operator Display
  37. 37. Shear Control
  38. 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. 39. Bar End Shape Acquisition Stereo Camera Single Camera
  40. 40. Crop Shear System Sensors <ul><li>Stereoscopic Width Gauge Camera </li></ul><ul><li>Single CCD camera measurement </li></ul>
  41. 41. Crop Shear Control System Optimisation & Tracking Installation
  42. 42. Crop Shear Control System Alternative Sensors <ul><li>Close Range Hot Metal Detector </li></ul><ul><li>Laser Speed Measurement </li></ul>
  43. 43. Benefits <ul><li>Potential savings through reduced yield losses are easily recognised. E.g. </li></ul><ul><ul><li>2 million tonnes per annum </li></ul></ul><ul><ul><li>Average Crop Yield Loss improvement 0.3% </li></ul></ul><ul><li>This exceeds a value of £300,000 per year </li></ul><ul><li>Further savings by reducing crop failures of £150,000 per year </li></ul>Total £450,000
  44. 44. Camber Measurement
  45. 45. CCD 2040 – EES Width Gauge <ul><li>CCD2040 Roughing Mill Camber Measurement </li></ul><ul><li>Second Stereoscopic Camera </li></ul><ul><li>Additional Real-time PC & Camera Interface </li></ul><ul><li>Camber Determination Algorithm </li></ul>
  46. 46. Camber Meassurement Camber Measurement Using 2 CCD Width Meters ~ 1M Plan View
  47. 47. Shape Measurement
  48. 48. CCD 2040 – Shape Measurement <ul><li>Laser module integrated into existing Stereoscopic Camera </li></ul><ul><li>Single Camera for Centre-height Measurement </li></ul><ul><li>Additional Real-time PC & </li></ul><ul><li>Camera Interface </li></ul><ul><li>Shape Determination Algorithm </li></ul><ul><li>Shape Compensated Width Calculation </li></ul>
  49. 49. Width Correction Uncorrected width Steel with lateral shape Corrected Straight line width Steel with lateral shape Uncorrected width Corrected arc width
  50. 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. 51. Shape Measurement Shapemeter / Width Gauge Combination
  52. 52. Thermal Profile
  53. 53. CCD 2040- EES Width Gauge <ul><li>CCD2040 Thermal Profile Measurement </li></ul><ul><li>Thermo-profile calculation using exposure time & video level data. </li></ul><ul><li>Thermo-profile HMI </li></ul>
  54. 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. 55. Thank you.

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