EMG - optimize forming process

1 EMG Automation India
EMG Automation GmbH
Optimizing the Pressing Process

EMG Facts & Figures
▪ 7 decades of experience
▪ global presence in more than 40 countries
▪ diversified product portfolio - focus on quality &
innovation
▪ 27,000 installation including 400 Quality
Assurance products
▪ local presence in India since 1993
▪ Independent subsidiary since 2008
EMG – Partner for the industry
EMG in Wenden –
Experience and expertise since 1946
EMG in India (Thane)

Quality assurance for your pressing process
■ Requirement:
Identification of the quality features for each sheet panel before it enters the press
■ Mechanical properties
■ Surface roughness
■ Oil layer
■ Material thickness
■ Surface quality
■ Target:
Optimisation of the pressing and coating process.

Quality Assurance for your pressing process

EMG IMPOC – Impulse Magnetic Process Online
Controller
online tensile strength and yield point measurement

Problem area – Length distribution
▪ typically two measuring values (beginning/end)
▪ statements on variations over strip length are not possible
▪ extrapolation along the total length is a questionable method

Problem area – Annealing process
▪ Today faulty annealing processes (or incorrect chemical analysis) cannot be detected
online and over the strip length;
▪ defective material will be delivered
EMG - IMPOC
Non-destructive material testing
140
150
160
170
180
190
200
0 100 200 300 400 500 600 700 800 900
Strip length in m
YieldpointinMpa
0,0
0,2
0,4
0,6
0,8
1,0
1,2
1,4
1,6
1,8
2,0
Degreeofskinpass/
Yielddeg.
Yield point Yield degree Degree of skin pass

The solution: IMPOCpro

IMPOCpro: The principle
Magnetic
inductive
measurement
(IMPOC raw
value)
Parallel
collection of
the results of
the destructive
testing
Modelling
IMPOC
provides
absolute
values for
tensile
strength and
yield strength

▪ 4 times sampling at an inspection line can be avoided!
▪ Reducing material rework
IMPOCpro: Customer‘s benefit
ThyssenKrupp Steel

EMG SORM 3plus – Surface Online Roughness
Measurement

Roughness measurement with stylus instrument
▪ Standardized roughness measurement with stylus instrument
sapphire tip  5 µm
electrical signal
Sampling frequency approx. 1.5 µm
(depending on device type)

Functional principle
α
α
Strip movement

Which parameters can be measured by SORM 3plus?
• Ra (Mittenrauheitswert)
• RPc (Spitzenwert)
• Wsa (Mittenwelligkeitswert in Arbeit)
Functional principle

Roughness documentation, especially for the automotive industry
SORM 3plus: Customer‘s benefit
Ra course offer different coils (Ra Stylus and Ra SORM)

EMG SOLID® - Surface Oil Layer Inline
Determination

1. Two halogen lamps emit infrared
radiation.
2. This radiation passes the oil, will be
scattered from the metal and passes the
oil another time.
3. The intensity of the back scattered light
is measured at four different absorption
wavelengths.
4. The actual measuring principle is based
on the Lambert-Beer-Law:
SOLID® – Measurement principle
Source: Infralytic GmbH
αd log I
I0

aluminium
housing
air & electric
connection
filter wheel
halogen lamp in
quick change
frame
sapphire window
detector
reference revolver
SOLID® – Measuring head components

SOLID® – The result from an electrostatic oiler

SOLID® – Benefits
■ unaffected by oil mixtures
■ high repetition accuracy of 0.1 g/m²
■ absolute and relative measurements possible
■ special EMG solution for keeping the lens clean
■ secure measuring distance of 120 mm

SOLID® – Technical details
Measuring method Infrared spectroscopic
Measured variable Area weight of the lubricant layer in g/m2
Measuring range
0.1 – 6 g/m² (measurements from 0.05 g/m² possible with special
calibration)
Measuring accuracy
Measuring range < 0.5 g/m² on request
Measuring range 0.5 - 2 g/m²: +/- 0.2 g/m²
Measuring range > 2 g/m²: +/- 10 % from measured value
Materials
all metal and non-metal surfaces with low glossy level, e.g.:
• Steel – cold-rolled strip, hot-dip galvanized, electro galvanized,
phosphated, aluminized, ZnMg surfaces, galvannealed
▪ Aluminum – uncoated, pre-treated
Lubricants Mineral oil, mineral oil thixotropic, Drylube (hotmelts)
Operation distance
(measuring position)
120 mm (traversing)
Strip height fluctuations
(measuring field depth)
+/- 10 mm
Ambient temperature +5 °C to +50 °C (extended temperature range with cooling)
Measuring frequency 60 Hz
Max. traversing speed 0.5 - 1 m/sec

■ Special solid state laser delivers 10.000 single
pulses per second
■ Robust and flexible quartz fibre bundles
transmit the light energy to the measuring spot
EMG SOLID® LIF – Measuring principle

Usable solution
EMG SOLID® IR EMG SOLID® LIF
Installation situation
Homogenisation rolls exist or can be installed
Not enough space for homogenisation rolls
Needed measuring range
< 0,1 – 6 g/m²
> 0,1 – 6 g/m²
Used lubricants
Oils with similar fluorescence characteristics
Oils with different fluorescence characteristics
and no oil mixtures
Oils with different fluorescence characteristics
and oil mixtures
Material surface
shiny / strongly reflecting
(e.g. bright-annealed stainless steel)
Selection criteria
EMG-SOLID® - The best of two technologies

EMG – Solutions in the automotive industry
Advantages of EMG system solutions:
▪ Online contactless solutions - future ready systems
▪ Transparency of the essential quality features for every sheet panel and coil
▪ Intelligent combination of systems: electro-mechanical and with respect to the
software environment
▪ Additional systems: thickness measurement / laser marking can be integrated
▪ Delivery and system integration from a single source
Consequences for production in the pressing plant:
▪ Improved process stability and reliability
▪ Transparency of input quality and targeted control of the forming process
▪ Minimized scrap and efficient material release processes through a joint database
and combined visualisation of the measured values

Quality Assurance for your pressing process

EMG Automation – Customers (extract)

EMG Automation GmbH
Industriestraße 1
57482 Wenden, Germany
www.emg-automation.com
info@emg-automation.com
EMG Automation India Pvt Ltd.
408/409, Lodha Supemus, Road No. 22
Wagle Estate, Thane – 400604, India
Mr. Ravi Asudani
Phone: +91 (0) 22 25801320
ravi.asudani@emg-india.com
Contact

More than 200 quality assurance systems used
by automotive steel producers worldwide!
Challenge us so that you can meet the demands
of your customers!
EMG – Your partner for QA systems

EMG - optimize forming process

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