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LASER MEASUREMENT SYSTEMS
Besides customized solutions, LAP manufactures products and applications with product features, that have proven their quality and reliability in metals industries.
Most of the times, the work to adapt these systems to the customers needs is easy, as only a few parameters have to be changed. Applications delivered previously can be modified easily for similar tasks. Still, every customer gets the solution that fits like a glove.
The advantages are obvious: experience from existing applications prevents from surprises and makes production faster.
SLAB CHECK
MEASURING SYSTEMS FOR SLABS AND BILLETS
Example: Measuring the position of the billet or slab before it enters the reheat furnace helps to control the charging of the billet, to optimize furnace utilization and to reduce the possibility of misaligned slabs.
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LAP measuring systems with
ANTARIS sensors are used to measure
width,
thickness,
length, side profile and position of slabs and billets.
LAP systems will optimize the casting process and control the cut-to-length operation. Precise readings of slab width, side profile, thickness, and length, allow exact determination of the slab weight and to document the output of the caster. In subsequent production stages these slabs can then be easily allocated to the customer orders on hand.
- Width, thickness, length
- Side profile and position
- For control of flame-cutting machine
- For positionning at the reheat furnace
- Application examples: Salzgitter Flachstahl GmbH, Outokumpu
PSG - PLATE SHAPE GAUGE
CTG / CTLWG
PSG: MEASUREMENT OF PLATE GEOMETRY
The PSG measures following properties of the material:
- Width
- Camber measurement
- Edge Profile measurement
- Length measurement
By measuring the plate contour behind the cooling bed, the subsequent processing steps of crop cutting, trimming, slitting, and cut-to-length are optimized. In addition to effective length and width of the plates, saber, necking, crop shape and side profile are taken into consideration to “best fit” the finished sizes into the plate, thereby achieving optimal yield. Crop cut optimization reduces scrap and increases yield and utilization.
For width measurement, laser distance sensors with special beam geometry are used to eliminate the influence of vertical plate movement on accuracy.
The plate side profile is assessed by scanning triangulation sensors. Head and tail shapes are measured by structured light imaging, projecting a laser line across the plate, using OPTARIS sensors to assess the outline measurement.
This eliminates parallax errors that would otherwise result from vertical plate movements. Assessing the complete plate geometry allows to perfectly control the trimming cuts. A monitor in the control pulpit graphically displays all results.
BENEFITS
- Compact measuring system for complete contour detection with all necessary sensors
- Full 3-dimensional measurement of plate geometry with all detailed information for crop optimization
- Minimum space requirements in the line, simple installation
- No measuring house necessary above the roller table
- Multiple use of the measured data within the combined system
- Very simple and rugged protective housing system for sensors and instrumental components (air cooling only, no water supply necessary, insulated housings)
- Integrated software package with integrated visualization
- Integrated interface to host system
COLD THICKNESS GAUGE / COLD THICKNESS LENGTH WIDTH GAUGE
The CTG is a 3 - track thickness measurement gauge with adjustable track positions. Optional length and width measurement can be added (CTLWG).
The system is typically positioned after both cold shears and suitable for plates with up to 100 mm thickness and up to 5500 mm width. The length of the plate is not limited.
LAP supplies two different concepts/combinations of mechanics and sensors depending on range for plate temperature less than 100 °C and between 100 °C and
300 °C.
THE MAIN ADVANTAGES OF THIS CONCEPT ARE
- One common measuring frame, incorporation all necessary sensors
- Minimum space requirements in the line, simple installation
- No measuring house necessary above the roller table
- Very simple and rugged protective housing system for sensors and instrumental components (air cooling only, no water supply necessary, insulated housings)
- Integrated software package with integrated visualization
- Integrated interface to host system
AUXILIARY SYSTEMS FOR COOLING AND PROTECTION
The entire measurement system is designed as a turn-key measurement solution including the auxiliary equipment for maintaining constant conditions for the measurement sensors. This is primarily required for the differential thickness measurement, as the distance between the sensors will directly influence the thickness readings.
Constant temperature conditions are not mainly required for the sensors, but for the inner steel frame supporting the sensors to eliminate thermal expansion. Therefore the entire inner frame is insulated and air-conditioned. Conditioned air will be supplied by an independent air conditioning system sized correctly for the application. The air conditioner will use ambient air and contains the blower, air filter unit and an air/water heat exchanger. The cooling water will be supplied by a compressor type water rechiller using a closed-loop water circulation. These two systems will normally be located close to the measurement location on the same floor or in the basement level below the measuring frame.
PERFORMANCE FIGURES
The conditions for the validity of performance figures are:
- Hot plate surfaces, typical rolled surface
- Surface free of water or scale
- Vertical movement of the plate maximum 50 mm
- Length accuracy is valid on the measured track
- Accuracy of thickness measurement is based on flat plates, virtual increase of thickness in case of unflat materials will directly influence the measured thickness
- Reference measurement on certified calibration pieces under cold conditions
THICKNESS MEASUREMENT
| For plate temperature < 100 °C |
|---|
| Resolution: | 0.01 mm |
| Repeatability: | ± 0.04 mm |
| Accuracy: | ± 0.05 mm (2σ; integration time 10ms at 100 measurements per second) |
LENGTH MEASUREMENT
| Resolution: | 0.1 mm (length) |
| Accuracy: | ± 0.1 % of measured length |
| Signal delay: | < 5 ms (measured at the analogue output) |
Signal acqui-
sition time: | typically 20 ms, depending on the signal quality |
WIDTH MEASUREMENT
| Resolution: | 0.1 mm |
| Repeatability: | ± 2 mm (under reproducible conditions) |
| Accuracy: | ± 3 mm (2σ; integration time 10ms at 100 measurements per second, calibrated measuring system) |
| For plate temperature 100 °C < T < 300 °C |
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| Resolution: | 0.025 mm |
| Repeatability: | ± 0.085 mm |
| Accuracy: | ± 0.1 mm (2σ; integration time 10ms at 100 measurements per second) |
DOWNLOAD APPLICATION REPORT
CALIX XL - LASER THICKNESS MEASUREMENT SYSTEM
CALIX series is the first family of LAP sensors for differential thickness measurement in one housing. They replace measuring frames, that need time-consuming recalibration and temperature control due to their temperature characteristics. The alignment of measuring beams is optimised during production at LAP. CALIX sensors don‘t need complicated adjustments of opposing sensors in the measurement frame. Errors related to alignment won‘t occur.
For wide material, measuring tracks in the middle of a roller table or for large movement ranges during traversing measurement LAP off ers CALIX XL. The measuring depth of more than 1 meter allows for enough movement in most applications, that may be realized without a stationary, massive O-frame.
LAP also designs rail constructions for your application, as well automated ones for traversing measurements as ones with manual handling for moving them out of the transport way and back in for measuring.
APPLICATION MOVIE
Two traversing CALIX XL laser systems measure the thickness of strip.
Customer: Haynes International, Kokomo (IN), USA
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BENEFITS
- Repeatability from ± 0,5 μm
- Measuring frequency: 4 kHz
- Measuring range: 30 mm
- Independent of material and surface
- Temperature-stable
- Low operating and maintenance costs
- Protection class IP 64
- Laser class 2
TECHNICAL DETAILS
| Measuring Range (a) | 30 mm |
| Throat height (b) | 200 mm |
| Throat Depth (c) | 1300 mm |
| Measuring Depth (d) | 1020 mm |
| Resolution | 0,5 μm |
| Repeatability* | ± 0,5 μm |
| Linearity* | ± 2,0 μm |
| Measuring frequency | max. 4 kHz |
| Laser power** | max. 1 mW |
| Laser class | 2 |
| Laser type, wavelength | Diode, 670 nm (red) |
| Beam divergence | 1,2 mrad |
| Signal processing | 80 MHz DSP |
| Interfaces | RS 485, Ethernet / UDP via
external / internal gateway |
| Power supply | 24 VDC, max. 500 mA |
| Protection class | IP 64 |
| Dimensions (HxWxD) | 800 x 300 x 1645 mm |
| Weight | aprox. 230 kg |
| Ambient conditions | 0 - 40 °C, 35 - 85 % rel. humidity, non-condensing |
* Test conditions: 20° C, matt white, averaging time 50 ms, 2σ
** more power possible
show all
STRAIGHTNESS CHECK
SETUP AND OPERATION
Short demonstration of applications in manufacturing of long products, using three different operation principles:
- laser micrometer (shadowing principle)
- laser light section
- laser triangulation
Non-rotating objects may need further measurement axes.
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STRAIGHTNESS VERIFICATION USING LASER-SCAN-MICROMETERS
For straightness measurement we recommend at least three micrometers. To detect deviations in all directions, rotating the tube is typically acceptable along its longitudinal axis during inspection. This typically is the case when measurement takes place after the straightener.
Quality verification of the bending of the sample (mm per 1 m, 2 m or 3 m). It is also possible to verify the diameter and ovality. Optionally the system can be upgrated to certify lack of hook ends.
Your benefit
- Inline measurement during production in real time
- Non-contact and high precision
- Independent of vibrations due to synchronization of data sampling
- Intuitive software for high speed data evaluation
- Data logging for quality assurance
- Easy calibration
- High durability
- Low maintenance
LAP CONTOUR CHECK
Wire, rod, bar, tubes - CONTOUR CHECK is THE solution for inline measurement of long products before, during or after rolling. Profiles may be round, square or hexagonal, glowing, hot or cold - CONTOUR CHECK measure relevant dimensions, detect changes in shape, rolling defects and surface defects. The system provides warnings if tolerances are exceeded so you can intervene before scrap is produced. Start-up times after product changes are reduced substantially by measuring from the first moment material comes through.
CONTOUR CHECK SETUP AND OPERATION USING THE EXAMPLE OF CC PROFILE
Short demonstration of applications in manufacturing of profiles.
- laser light section
- variable configuration
- measurement of complete profiles
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THE RIGHT SOLUTION FOR YOUR ROLLING MILL
LAP CONTOUR CHECK provide all the information needed for fast and precise adjustment of rolling lines. Depending on model, they can measure rounds, rebar, flats, squares, hexagons, L-, U-, T-, H-shaped profiles or even rails. The patented TrueShape technology allows precise measurement of three-lobed or polygonal rounds, and of single-sided over- or underfill. Off-size conditions are immediately displayed and allow corrections during runtime of a billet. Elimination of sample cutting reduces the ramp-up time after size or product change. Precise determination of off-size lengths at head and tail allows crop-optimization, further increasing the yield.
Rolling process with possible application points of CONTOUR CHECK gauges
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PROCESS OPTIMIZATION AND QUALITY CONTROL
Your customers' satisfaction depends on the quality of the products you provide. The quality depends on your control of the production process. For control you need precise, detailed, reliable information delivered in real-time.
LAP CONTOUR CHECK provide this data. For control and documentation.
- real-time process monitoring
- check dimensions and show trends
- detect rolling defects and offer solutions
- detect singular and periodic surface defects
- connect several CONTOUR CHECK for comprehensive process analysis
To enlarge please click on table.
MEASURING PRINCIPLE
To enlarge please click on image.
To enlarge please click on table.
MEASURING PRINCIPLE
To enlarge please click on image.
DOWNLOADS
Laser Measurement of Contour on Rolled Profiles
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