STEELMASTER

Non-Contact In-line Dimension Measurement in the Steel Industry.Dependable Solutions for Hot Rolling and for Quality Control.

L

2

Wire Rod, Bar, Rebar, Profile, Tube, Pipe – Hot, Cold, Quality Control

•Closertolerances(1/2,1⁄4DIN)•"Zerofault"•100%qualitycontrol•Higherproductivity•Fasterstartup•Lessdowntime•Lessmanpower

Toremaincompetitiveasasteelmanufacturer, the latestand most advanced technologies are needed to ensurethe best product quality and maximum output. Amongothers,onechallenge is toobtainkeydatawhichallowsto increase the productivity and improveproduct qualitywhilstremainingcosteffective.

STEELMASTER gauges and systems. They are based onlatest technologyandon theexperiencewithmore than300unitsinhotrollingandsimilarprocessesandtheyarebacked by many thousand ODAC scanners, operating incoldprocesses.

Outstanding AdvantagesForeasyintegration,dependableoperation,dataprocessinganddisplay:•Hi-Techlaserscannerswithutmostprecision•Upto6000measurements/s•Onesingle(fibreoptic)cablebetweenLPOandCPO•CompactindustrialPCwithhighestworkingreliability•HighlydevelopedSTEELMASTERsoftware•Specialsoftwaresolutionsforpolygonalshapes•Sophisticatedmechanicsandprotectionsystem•Closetozeromaintenance–quickandeasycleaning

Modernin-linemeasuringsystemsnotonlyprovideaccuratevaluesfordiameter,ovality,width,heightetc.,buttheyalsodetectshapedeviations,rollingfaultsandotherprocessproblemsinstantly.STEELMASTERsystemseasilymeettheserequirementsthankstohighmeasuringrates,intelligentsoftwareandoscillatingorrotatingmeasuringmodesandothers.

Dimension Measurement

Longitudinalfaults

Shape Deviations, FaultsRadialfaults

Upto1000measurements/s(optionally2000measurements/s)

At100m/s L=100mm/4in.(optionally50mm/2in.)

Diameters canbemeasured in1orinupto6axes.Alsocombinedwithoscillation. Outsidedimensionsanddiagonalsaremeasuredaccuratelyandindependentofproductorientation(twist).

DIMENSIONMEASUREMENTANDFAULTDETECTION

WHATTHEMARkETDEMANDS OURSOLUTIONS

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ExactmeasurementofD1...D4,blindzonesbetweenmeasurementaxes

SMO... Oscillating GaugesTheyareable tomeasureroundandnon-roundproductssuchassquares,hexagons,flatsetc.,independentoftwistand twist angle.This is made possible through dynamicregressionanalysiswithsophisticatedsoftware.Dependingonthemodel,thenumberofmeasurementaxes(scanners)canbe2,3,4or6.With an increasing number of axes, more data can becaptured at the same time, and the measurement cycleperprofileisshorter.SMOgaugescanalsobeoperatedinstaticmode,inselectableorientation.

Outstanding Advantages• Measuresalltypesofproducts• Independentoftwist• Veryshortmeasurementtimes• Alsocomputescrosssection(area)

SMS... Static GaugesSimple, compactandprimarily suited for roundproducts.SMSunitsareofthesamedesignasSMOsystems,withtheexceptionoftheoscillationmechanism.Theyareextremelycompactandeasytointegrate.

Dependingonthemodel,thenumberofmeasurementaxes(scanners)canbe2,4or6;othermodelsonrequest.

Outstanding Advantages• Extremelycompact• Veryhighmeasuringrate• Nomovingparts

α=upto180°

1to6measuringheads

1to6measuringheads

Blindzones

12

3

4

1 23

4

1to3measuringheads

ExactmeasurementofW,H,D1,D2

ExactmeasurementD1...Dn,max.,min.ComputedareaA

A

max.

min.n

TwistD2D1

HW

ExactmeasurementofW,H,D1,D2

ExactmeasurementD1...Dn,max.,min.ComputedareaA

A

max.

min.n

TwistD2D1

HW

5

6

5

6

SMR... Rotating GaugesFor round and non-round products such as squares,hexagons,flatsetc.Speciallydesignedforhighproductionspeed and short length.These gauges are based on thesamewellprovendesignastheoscillatingSMOsystems,howeverwithanovelfullycontactlesstransmissionsystemforbothpowerandsignals.Thankstothisuniqueconceptandthehighrotationalspeed,thefullprofile iscapturedwithin fractions of a second, allowing thus to minimizescrap production and to guarantee tighter tolerances.Twistand twistangledonotaffect themeasuring resultthankstoanintegrateddynamicregressionanalysisinthesoftwarepackage.Dependingonthemodel,thenumberofmeasurementaxes(scanners)canbe1,2or3.

Outstanding Advantages•Significantlyincreasedmeasuringratepersecond•Capturesatleast3profilesinlessthan1second•Alsocomputescrosssection(area)•Highreliabilitythankstothefullycontactless transmissionofpowerandsignals•Slimdesign

STATIC•OSCILLATINg•ROTATINg–THEBESTSOLUTIONFORANyAPPLICATION

X

X

X

d

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Video

LaserscanThelaserbeamscansathighrates,typically1000/s(optionally2000/s)

Measureddimensiond(orthogonaltolaserdirection)

Outputsignaltoprocessor

Pulsecounter

ODAC®laserscannerswithlatestopticalandlasertechnologyaretheheartoftheSTEELMASTERgauges.Thefieldexperience,gained fromover65'000performingODAC® scannersandsystems, representsa solidbase fordesign refinementsandquality.ZUMBACHoffersmodelswithmeasuringfields from2upto500mm(.08upto19.68in.);biggermodelsuponrequest.

ReceiverEmitter

LaserbeamMeasuringfield

PrinterUSB

Remotescreens

Customernetw

ork(Ethernet)giantdisplayRS-422

FibreopticcabletoLPO

Alarms,startstatisticsetc.

STEELMASTERsystemsallowforoptimumconfigurationandlayoutofthemeasuringunit(s),processor,auxiliarydevices,networksandperipheralsforeachrollingmill.

LPO(LocalProcessingandOperationunit)

CPO(CentralProcessingandOperatorunit)Ascabinet,incl.TFTetc.oras19"rack

Blower/Filterunit(gE)

giantdisplaywith2,3or4lines

1–10remoteworkstations(PC's)forcommunicationoverETHERNETTCP/IP

Remoterepeaterscreenandkeyboard

Pyrometer

ETHERNETTCP/IP

Option:coolerorheater

max.20m(65ft.)

Fibreopticcable,max.500m(164ft.)

Upto4measuringunitsandLPO's

Outstanding Characteristics•Extremelyaccurate•Permanentlycalibrated•Highresolution•Highmeasuringrateofup to1000/s/axis(optionally: 2000/s/axis);6000/sfor6axes•Highimmunitytodirt•Totallyindependentofposition,vibration,temperatureofrolledproduct,lightintensityetc.

•Wellproven,extensivelifetime

SySTEMARCHITECTURE

THESENSORS

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SMO... Oscillating GaugesForroundandnon-roundproducts(squares,hexagons,flats,rebaretc.)• Upto6measuringaxes• Seamless360°coverage• Noblindzones• Measurementindependentoftwist• Computesalsocrosssection• Oscillatingorstaticoperation

SMS... Static GaugesEspeciallysuitedforroundproducts• Upto6fixedaxes• Nomovingparts• Extremelycompact• Practicallynomaintenance• Extremelyfastmeasuringrate, shortmeasuringdistances• Mosteconomicversion

These units comprise the individual sensors (scanners), sealed from the harshmill environment bymeans of a uniqueprotectionsystem.Reliablefunctionisguaranteedthankstoanefficientairpurgingandcoolingsystemand,ifneeded,byawatercirculationsystem.Specialservicedoorsprovideeasyaccesstocleanthewindowsfromdust,howeverthisisrarelyneeded,thankstotheefficientairpurgingsystemwhichisstandardforallZumbachgauges.

SMR... Rotating GaugesForhigh-speedproductionsofroundandnon-roundproducts(squares,hexagons,flats,rebaretc.)•Upto3measuringaxes•High-speedseamless360ºcoverage•Upto100rpm(min.3fullprofilemeasurements/s)•Highreliability(fullycontactlesspowerandsignaltransmission)

•Rotatingorstaticorientableoperation

Alocalprocessingandoperationunit"LPO"isinstalledatmax.20m(65ft.)fromthemeasuringunit.Itpre-processesandfiltersthemeasuredvaluesinrealtime.Thedataissentviaonesinglefibreopticconnectiontothecentralcontrolandoperatingunit"CPO".Theheartofthe"CPO"isanindustrialembeddedPC,featuringallnecessaryinputsandoutputsfordisplayunits,printerorotherperipherals,Ethernet(TCP/IP)forcustomer(see"SystemArchitecture").

Anoptionalopticalpyrometercanbeusedtoprovidetheproducttemperature;thisinputisusedtocorrectthehotdimensionsintocoldcorrectedvaluesbeforebeingdisplayed,allowingthusrapidjudgementsbytheoperatorforanymilladjustmentsrequired.

STEELMASTERMEASURINgUNITS

STEELMASTERDATAACqUISITION,PROCESSINg,DISPLAy

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Basic Software PackageSTEELMASTERAll functions for round products•Displayofmeanvalue,min.,max.,ovality•Hotand/orcoldvalues•Min./max.alarmlimits•Personalizedscreen•Sectionscreen•SplitscreenincaseofMULTIgAUgE•Trendgraph•Headandtailscraplengthindication•Productrecipe•Producttable/memory•Statistics•Printingreports•Maintenance,calibration

Sub-ModulesSTEELDATADatafiltering,preprocessing,computation

STEELGAUGESystemconfiguration

Thisisahighlydevelopedsoftware,provenandrefinedovermanyyears.Abasicpackageoffersallfunctionsneededforroundproducts.For all non-round products, such as squares, hexagons,flats,rebaraswellasforpolygonalshapedeviations(3-rollblocks),additionalsoftwaremodulesareavailable.Also for additional functions such as networkcommunication,dataarchiving,remoteworkstations,SPCstatisticsetc.,optionalmodulesarereadilyavailable.

Unique: There is only one hardware and software for all STEELMASTER versions, which can be upgraded any time.

Themaindatasuchasmeasuringrate,accuracy,measuringparametersandalloptionalupgradesarethesame.High flexibility allows for individual configuration of thescreens with section and trend displays, (numeric andgraphic), printing reports, statistics etc. as per specificneeds, and operating methods. Several programmableaccess levels andpasswords allow for optimumuseanddatasafety.

The state-of-the-art software allows an almost unlimitedselection for the graphical and numerical display of thenumerousparameters:

MULTIgAUgEdisplayof4measuringunits

PROFILESForsquares,hexagons,flats,specialprofiles

REMOTE STEELMASTERFornetworkingviaETHERNETTCP/IP,withupto10independentPCworkstations

STEELDATABASEForpostproductionviewingandarchiving(tobeinstalledonexternalPC's)

STEELHOSTStandardprotocolforETHERNETTCP/IP

SPCForSPCstatistics,configurable

REBARForrebarwithvariousgeometries

POLYGON / EPM / FPSEPMsoftwareforroundsandhexagons,forspecialasymmetricshapesandforthedeterminationofoutofroundconditions

EPM, the new Method and Software for Special Product GeometriesZUMBACHdevelopedanovelmethod,EPM(EnhancedProfileMeasurement,pat.pend.) forgeometrieswith irregularorasymmetric shapeaberrations (e.g.asymmetricoverfill orunderfill). Inparticular it is alsoable to captureand calculatepolygonalshapes,whichcanoccurincertainrollingprocessesoraftersubsequentpeeling/grindingoperations.Forany shape itwillmeasureathighaccuracynotonlymin.,max.andmeandiametersbutalso the trueout-of-rounddeviationRONtasdefinedbyISO/TS12181-1aswellastheinscribedcircleMICIandthecircumscribedcircleMCCI.AnoptionalmodulenamedFPS,especiallyfor3-rollblocks,is available for calculating accurate values formin.,max.,mean diameter and ovality, corresponding to the valueswhichwouldbefoundbymanual3-pointmicrometerscrews(ifbothreadingsarerelatedtoroomtemperature).ThisFPSmodule additionally calculates the "Touch" and "gap"diameterswhichareessentialfortheinitialrollsetting. 3-lobed 6-lobed Irregular Asymmetric

Software Options

STEELMASTERSOFTWARE

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TheSTEELMASTERhardwareandsoftwarepermitstoconnectupto4measuringunitstothecentralPCandtoprocessanddisplayallsystemssimultaneously.Thisconfigurationhasprovedhighlysuccessfulovermanyyearsbecause:

• Itprovidesabetterandquickeroverviewandfullprocesstransparency• Itiseconomical•Substantiallysmallerinvestment

Theillustrationsshowsometypicalconfigurationsthathaveallproventheirefficiency.

Bar Mill

Rod Mill with Pre-/Post finishing

IntermediateRoughing

Rod Mill

Intermediateorprefinishing

Wirerodblock Postfinishing

Double Rod Mill Combined Bar/Rod Mill

Intermediate

Prefinishing

Finishing

3-rollblock

General Data of the Measuring UnitsMeasuringprinciple Laserscanningtangential(shadow)Measuringrate Upto1'000/s(optionally2'000/s)peraxis*Laser Laserdiodered,classIINumberofmeasuringaxes 1...6(dependinguponmodel)Resolution 0.001mm(.00004in.)Repeatability Typically±0.01mm*(.0004in.)Measuringtimes SMS: 1measurement(allaxessimultaneously)in1...20ms*(dependinguponmodel) SMO:1completeprofilein0.4...4s SMR:1completeprofilein0.1...0.3sOscillationangle Programmableupto180°**Dependinguponmodelandversion

Standard Models

Furthermodelsareavailable,dependingonproductandmeasurementrange1)Max.diameter=dependingontheguidingandvibrationMin.diameter=approx.1mm(.04in.)2)X=Numberofmeasuringaxes

Pleaseaskfordetailedliteratureaboutdataanddimensionsoftheindividualmodels.

•Technicalspecificationsaresubjecttochangewithoutnotice

MULTIgAUgECONFIgURATIONS

Model Measuringfield Max.productdiameter1)

mm Inches mm InchesSMS/SMO/SMR100-SX2) 100 4.00 80 3.2SMS/SMO/SMR160-SX2) 160 6.30 135 5.3SMS/SMO310-SX2) 310 12.20 280 20.0SMS/SMO550-SX2) 550 21.65 500 20.0SMS/SMOXXX-SX2) Specialrangesuponrequest

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TheZUMBACHGroup •ZUMBACHAgencies

STEE.002.0002.EJUN.11