TBK laser measurement equipmentContactless measurement for optimal production processes

Tailor-made measuring solutions for long productsWhere experience meets innovation

TBK Automatisierung und Messtechnik GmbH, located in Graz, Austria is SMS group´s center of competence for laser measuring equipment and a 100-percent subsidiary of SMS group.

TBK Automatisierung und Messtechnik GmbH has been developing measurement technology solutions for the steel industry since 1986, in particular laser measuring systems based on the light section method. The two companies TBK and SMS group have been working closely together since 2004.

TBK offers tailor-made solutions for dimension control and surface analysis of rolled products for the long product plant range, including wire rod, bars, sections, or rails, as well as tubes or semi-finished products such as continuous cast billets or blooms. Straight-ness measuring equipment, especially for rails, and instruments for measuring special profiles and wheels complete the product range.

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TBK uses the Light Section Method. This method al-lows the entire contour of the product to be examined, regardless of its shape.

For this purpose, special lasers project lines onto the surface of the product. The reflected laser light is captured by cameras and converted into distance values. TBK systems are able to calculate the precise cross section of the product using these values. The high-resolution and high measurement density enables the creation of a 3D model of the product, which also recognizes surface defects.

Conventional laser measuring systems use the shadow method and are capable of taking random measure-ments of only some dimensions, such as the height or width of a product, for example.

Systematic quality improvement based on meas-urement data Based on the high-precision cross-section measure-ments, TBK systems generate precise information that is relevant for rolling process control and upload it back into the production system. Depending on the plant layout, the models are displayed on the plant operators’ workstations or are automatically analyzed by SMS group control systems to improve product quality and efficiency.

Sophisticated sensors for perfect measurement results High sampling rates, short exposure times, and absolute synchronization are key features that set TBK sensors apart from other light section sensors on the market. These properties mean TBK sensors offer maximum pre-cision and detailed mapping of the current cross-sec-tion contour. The sensors function reliably even at high rolling speeds or under difficult conditions, for example when material is conveyed rapidly or vibrates heavily.

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Contour measurement with light section sensors Technology for high precision

Shadow method Light section method

6 measuring points Diameter measurement only using contour interpolation

400 measuring points Mapping of true cross-section

Unique technology for every cross-sectionIn order to capture complex contours fully and pre-cisely, TBK sensors light up different contour regions with various laser colors – an essential basis for synchronous measurement. In this way, overlapping areas can also be differentially mapped and precise cross-section models generated. Combined with the camera control system developed by TBK, fully synchronous recordings can be made of different contour areas. This minimizes the influence of rapid lateral movements on the precision of the measure-ments.

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Combining different laser colours ensures the over-all contour can be cap-tured with precision.

Calibrate once – use any time The position of the TBK sensors relative to one an-other is determined during calibration, which should be performed at regular intervals. The TBK software automatically determines all the necessary parameters using recordings from a certified calibration unit. Con-sequently, no re-calibration or mechanical adjustments of the measuring system are required for a product change – production can continue uninterrupted.

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Benefits of measuring systemsContinuous monitoring of ongoing production to reduce operating costs

The demands being made in terms of the dimensional accuracy and quality of the products are increasing. In addition, the production process must be monitored to optimize yield and production time utilization. To satisfy these demands, plant owners need to know the current state. They must be able to react quickly at all times to deviations in the production process.

Process and product information allow operators to im-prove yield and productivity, thereby resulting in lower operating costs.

TBK measuring gauges offer direct and continuous feedback on dimensions and weight per meter indica-tions. The benefits of this are:

n No manual sampling for dimensional checks or measuring of start-up bars required = reduced delay times

n Less out-of-tolerance material = increased yield

n Rolling minimum weight per meter = saving material and energy

n The information available enables operator to optimize mill adjustment for rolling minimum or optimum tolerances

This can be transferred into direct savings in operating costs. What’s more, increased time utilization saves idle time costs and allows more products to be manu-factured using direct feedback on the product informa-tion and a reduced sampling time after a roll change or dimensional check during production.

Sample calculation based on average sales prices and typical idle time costs per hour

Tolerance and yield improvement

Weight or yield Production Sales price Total savings improvement(%) (t/a) (€/t) (€/year)

0.20 500,000 500 500,000

0.50 500,000 500 1,250,000

1.00 500,000 500 2,500,000

2.00 500,000 500 5,000,000

3.00 500,000 500 7,500,000

Manual sampling savings

Samplings Shift/ Stop time Idle costs Total cost per shift year (min) (€/hour) savings (€)

1 960 20 3,000 960,000 1 960 20 5,000 1,600,000 1 960 20 10,000 3,200,000

2 960 20 3,000 1,920,000 2 960 20 5,000 3,200,000 2 960 20 10,000 6,400,000

3 960 20 3,000 2,880,000 3 960 20 5,000 4,800,000 3 960 20 10,000 9,600,000

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TBK gauges are characterized by the following features:n High measuring frequencyn Robust housing suitable for rough mill operationn Laser and camera installed as sensor and calibrated in

workshop, allowing for a plug and play maintenance systemn No moving partsn Water-cooled frame with temperature stabilization unitn Measuring window size / precision standardized and to

customer specificationsn Cooling by water and ambient air to ensure close tolerances

and long lifetime of sensorsn Lenses cleaned by conditioned compressed air n Gauge can be moved out of the line for maintenance workn Calibration interval every 14 daysn Maintenance-friendly sensor arrangement

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Competencies and portfolioThe right solution for each product

TBK systems can be utilized for the full range of long products including wire rod, bars, tubes, sections, rails and special profiles, as well as continuously cast billets and blooms. Our portfolio covers the following applica-tions:

n PROgauge laser measuring system for section and rails (hot and cold condition)

n MEERgauge® laser measuring system for bars, wire rod and tubes (hot and cold condition)

n REBARgauge measurement of dimensions and determination of weight per meter for rebars

n PROwave straightness laser measuring system for rails, sections and tubes, and rail waviness

n Dimension measurement systems for billets, bloom, slabs, wheels, and special profiles

n SurfTec surface defect detection system for sec-tions, rails, bars, wire rod, and tubes

Benefits at a glancen Measurement of various contoursn Information on complex key performance values

helps operators make appropriate process-relat-ed decisions

n Stable measurement resultsn Individual tolerance specifications taken into

accountn Software and measuring unit are individually

tailored to production conditionsn Profiles can be changed without intervention in

the measuring unit; the software is switched over automatically

n Time and cost benefits through optimization of production

n Individually adapted laser power

PROgaugeFlexible measuring system for a wide range of beams, sections, rails, and special profiles

The product diversity in the field of light, medium and heavy section production is especially challeng-ing when it comes to contour measurements. With particularly large formats, such as beams with web heights of over one meter, the measurement windows must be correspondingly wide. That is why top priority must be given to the mechanical stability of the sen-sors in relation to each other. Design-related measures and air or water-cooling are used to provide effective compensation for the high thermal loads.

Features of robust sensor technologyn Four or eight PxD sensor headsn Up to four laser colors for synchronous acquisitionn Internal product database for tolerances and

shrinkage factorsn Customized Level II interfacen High-speed output to surface defect detection

(SurfTec)

Quick format changes Changeovers from one section type to the next are performed fully automatically, with no need for oper-ator intervention. This results in significant time and cost benefits during production as well as increased plant availability.

Special solutions for large sizes If required, the experts at TBK can provide special frame designs to attain the necessary size of the measurement window (width from 160 to 1300 mm). Sensors with high laser capacities of up to 500 MW are included in the TBK technology portfolio and have been tried and tested many times. The measurement window format and the accuracy requirements speci-fied by the plant owner determine how many sensors are used. This means even oversized sections can be measured reliably.

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The MEERgauge® laser system for bars, wire rod, and tubes uses four sensors. A true-shape cross-section is created from up to 400 synchronous measuring points in a shared coordinate system, and is then displayed with maximum precision. Unlike with conventional systems, the true shape of the contour can be repre-sented precisely. With no moving or oscillating parts, the system requires almost no maintenance.

Roll adjustment under closed loop control TBK measuring systems allow for closed loop control between the contour measurement and rolling mill con-trol systems. The computer-based interpretation of the measurement results allows roll adjustment corrections to be made while production is ongoing. As a forerunner in terms of the measuring speed – which is a key quality criterion for measuring equipment, especially in the

field of wire rod production – TBK systems operate at rolling speeds of up to 120 m/s. Short exposure times and synchronized measurements by all sensors mini-mize the influences of the cross motion of the product.

Benefits at a glancen High measurement data density:

up to 6 million measuring points per secondn Short exposure time and absolute synchroniz-

ation of the measuring probesn Measuring equipment in the immediate vicinity

of the roll standsn Direct transfer of measured values to the roll

stand control system (closed loop control)n Compatible with 2-roll and 3-roll systemsn Time and cost benefits from direct production

control

MEERgauge®

Measuring systems for bars, wire rod, and tubes with monitor control system

Key values to be extracted out of accumulated cross sections consecutively taken during rolling of the rebar:

n Width of seam (longitudinal rib)n Core diametern Height of cross rib (upper and lower rib)n Height of rib in defined anglen Weight per meter

REBARgaugeDimension and weight control for rebars

TBK has developed a gauge to measure rebars that allows mill operators not only to control the conditions of the ribs but also to roll in a reliable manner close to the minus tolerance. In addition, the condition of the ribs with regard to roll wear can also be monitored. The gauge can be installed either in rebar mills or in wire rod mills used to produce rebars, plain bars, or wire rod.

Allrightsreserved•  MiddleEastIron&SteelConference,Dec.2018

23.Mai2019

CrosssecAonofrebarasmeasured SecAonsalignedinnormalizedposiAon

1

Cross section of rebar as measured

Sections aligned in normalized position

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PROwaveStraightness and wave measurement

TBK also offers straightness measuring equipment for rounds, tubes, sections, and rails. This is typically done after straightening or finishing.

Rails are one of the most demanding sections with regard to straightness and represent a good example of the contact-free, continuous measuring system PROwave.

The rail straightness and waviness are tested in the rail test center. Increasing demands on the straightness and flatness of rails are a consequence of railroad re-quirements for higher speeds and on-track loads. This requires precise knowledge of the current quality level of the product as well as rapid responses to changing process parameters. The exploitation of tolerances, minimum interruptions in production, and high yield rates guarantee economic success.

Measurement principleUltra-precise laser sensor images are taken of the head contour of rails over the whole rail length. The waviness of the surface on the exact center line of the head and in a horizontal direction 14 mm below on the side of the head is determined. Derived from tradi-tional specimen measurements, the display includes a graphics representation of the real shape of the length and position and provides direct information on the current straightening process. The recognition of trends enables reliable production within tolerance limits and proactive corrections on the finishing line.

Cord shifting methodThe technique used here is the cord shifting meth-od, with which 3 or 4 lasers at a defined distance from each other are shifted along the rail and detect the bending curve, as shown in the graph below. A minimum of three sensor heads supply information synchronously on the distances to predefined points on the surface of the rail head. The application of the cord shifting method provides initial information on the waviness of the rail that is not influenced by the movement of the rail on the roller table. This system can also be used for tubes, round bars, and sections.

PROwave straightness measurement system

Anlagen zur Roheisen- und Eisen-schwammerzeugung Headline zweiten Grades

Special applicationsSpecial solutions for rings, wheels and continuous cast products

TBK technology is already being successfully used for various special applications, including measurement of the contours of rings and wheels. Whatever the ap-plication: The TBK sensor specialists are hard at work in the fields of measuring technology, automation and software to deliver customized solutions with tangible benefits for plant owners.

The technological principle of line triangulation and the derivation of relevant key data from the contour compiled are suitable for any kind of shape or dimen-sion control.

Wheels and ringsn Creation of total cross-section from partial data

recordingsn Calculation of dimensional key characteristics from

the total cross-sectionn Detection of product eccentricityn Comparison with templates, set points, and toler-

ance bands

Continuous cast productsContinuously cast billets, blooms, or slabs can also be measured. In addition to measuring the size and shape, the system can detect the condition of the surface. Either one unit can be installed after the continuous caster, or one unit each in every strand. This provides direct feedback on the condition of the cast product, allowing the operation of the caster to be monitored and adjusted accordingly.

Benefits at a glancen Tailor-made solutions based on customers’

requirementsn Measuring technology and software indi-

vidually combinedn Product-specific set points and tolerance

limits taken into accountn Centralized evaluation and distribution of

measurement data to visual display unitsn Time and cost benefits thanks to optimized

production processesn High sampling rates for detailed rep-

resentation

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SurfTecAutomatic detection and allocation of surface defects on the hot product

With TBK measuring systems mill operators can check their products continuously for surface defects by fully automatic means and while production is still under-way. For this an analysis model creates a 3D model from the high-resolution cross-section measurements. High measuring frequencies provide the required pre-cision: the system shows precise details of even slight anomalies on the surface.

Troubleshooting with intelligent fault analysisIn the case of products for complex applications, such as the automotive or mechanical engineering sectors, for example, the tightest tolerances apply to the di-mensions guaranteed. Nevertheless, every production line experiences minimal anomalies that are caused by the ingoing material or minute damage to the rolls or guide rollers, among other things. Mill operators are therefore faced with two challenges:

First, they need to detect and locate defects on the hot surface that are not visible to the naked eye in time. Secondly, they need to identify and eliminate the cause.

The surface measurement system from TBK helps plant owners to do both: It determines the precise position of the anomalies on the surface at the time of rolling, evaluates the data using special algorithms, and provides the plant owner with information on the cause by classifying the defects. In this way, it is pos-sible to determine quickly whether a roll is damaged or whether defective ingoing material has been supplied. The time advantages are two-fold:

n Increase in material output due to quick response in the event of surface defects

n Improvement in the productive time of the whole plant, as the causes of anomalies are identified far more quickly

n Classification of defects and correlation to process anomalies

The TBK surface analysis system increases pro- ductive times and material output.

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Automatic troubleshooting

The surface analysis software looks for local, atypical anomalies on the surface and classifies the data. Using special algorithms the sytem then provides the plant operator with important information on potential causes.

Reconstruction of an H-Beam with a surface defect in one of the flange ends. (Colors indicate deviations from the ideal cross section.)

Outline of the process that reconstructs a 2D surface map from individual cross sections.

Periodic deviations are caused by damaged rolls or guide rollers.

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Relevenat key values from tried and tested algorithms It is usually plant operators who make decisions regard-ing production control, and relevant and precise key performance values provide a reliable basis for this. In addition to standard, established values, TBK measure-ment systems provide a wide product-specific range of dimensional parameters. Tried and tested algorithms that have proven to be effective are used to generate performance values from the measured contour data.

Fully automatic plant control The direct transfer of data from the measuring unit to an online control unit allows the rolling mill process to be controlled fully automatically in conjunction with the advanced system concepts supplied by SMS group. This offers a number of advantages:

n The precise measurements and data displays are a valuable input when it comes to making the right decision, even for the most experienced rolling mill operators.

n The computer-assisted systems react within a frac-tion of the time an operator would normally require.

n The TBK sensors record format fluctuations that are not picked up by conventional measuring systems and cannot be seen by the naked eye.

n These automated systems mean less manpower is required in the rolling mill.

Industry 4.0 rolling mill The aim of all mill operators is to maintain stable mill operation with high time utilization and consistent product quality. A fully automated system of production control and data collection is a basic requirement of digitalization.

Furthermore, to adjust and adapt the process according to different conditions, process data are required in ad-dition to data on the product conditions. The TBK gauge collects data on the condition of the finished product including its geometry, shape, dimensions, surface con-ditions, and on the temperature or rolling speed.

Sophisticated measuring technology ready for industry 4.0Automatic collection of product data is key to digitalization

The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these charac-teristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.

TBK Automatisierung und Messtechnik

Schmiedlstrasse 88042 Graz Austria

Phone: +43 (0) 316 405 5740office@tbkautomatisierung.atwww.tbkautomatisierung.at

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