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The detection of soil erosion processes in dams, hydraulic heave failure or corrosion processes of reinforcing steel in concrete are a small selection of measuring applications in civil engineering where the impedance analysis can be used to determine the measurand. Those measuring applications are having high requirements for the measuring hardware. For example a common interface for fast data exchange, high resolution, independent functionality and easy customizability to suit the measuring application. For that reason, a well-known application for steel-mill process monitoring can be used as a development platform. This hardware platform is based on a vector network analyzer and is meeting the requirements mainly. However, a couple of modifications has to be made, like replacing the ADC for a higher sample rate, Ethernet for easy and fast data exchange and the microcontroller for more calculation power.
Process Monitoring in Steel-Mills using Impedance Analysis: VNA Improvement for Data Acquisition
(2017)
The process automation extends over every manufacturing step of a product in the steel-mill to increase the quality, quantity and energy efficiency. The product dimensions are an important part of the quality control; these must maintain the specified tolerances. Additional to the cross-sectional-area, the measured data contains much more information about the manufacturing process, e.g. eccentricity, condition of the rolls and defects of the rod. For analyzing the measured data and to gather more information about the manufacturing process it is necessary to increase the speed of the data acquisition by performing some modifications of the VNA, e.g. faster analog to digital converter and microcontroller, improved firmware and optimized values of the passive electrical components for faster time constants and transient responses.
Rolling mills are continually improved and opti-mized by implementing innovative technology to decrease costs and scrap. Despite of the progressive automation and experience, some important process parameters can still not be determined with sufficient accuracy. As part of the research project PIREF, the velocity of the hot rolled rod shall be measured by using im-pedance analysis to estimate the volumetric flow rate of the mate-rial. For a high accuracy measurement of the impedance, a pow-erful VNA is used. To minimize errors in the measurement, caused by e.g. temperature drift, a correction of the measurement fre-quency is needed. This must be achieved without recalibration of the VNA to avoid faulty behavior of the online control. To solve this problem, an approach based on a polynomial regression is presented in this work.
Quality and dimensional accuracy of hot rolled steel rods depend on several process parameters. In fact many of these crucial parameters are not be sufficiently determined yet. By improving automation and process control costs and scrap of production can be decreased. As part of the research project PIREF, one of these parameters – the roll gap – is under investigation beside other topics. Before starting rolling, the roll gap is typically set to a fixed value according to the planed dimensions of the product, but the forces during the rolling of the rod cause an enlargement of the roll gap. In which way the rolls change their position and form shall be examined in our research project. Therefore a first experimental setup has been built up to determine the change in position of the rolls under applied force. This is realized by a pot core coil as sensor using impedance analysis. The first results are presented in this work as a proof-of-principle.
Process diagnosis is an important method for improving product quality in rolling mills. In addition, the measurement of process variables such as roll gap, cross-sectional area, velocity, and volume flow of the material during production enables the implementation of model-based control concepts to improve product quality. The non-contact speed measurement of hot wire and bar is still a big challenge due to the rough environmental conditions and is solved mainly with optical measuring methods in production. The alternative measurement principle with eddy current sensors presented in this paper enables velocity measurement at locations in a rolling mill where optical measurement methods are not suitable.
In the field of producing hot-rolled steel bars and wires, hot rolling mills are incomplete or barely equipped with measuring technology for recording relevant process parameters. Therefore, there is a big potential to increase product quality and to decrease costs and scrap by improving process control establishing new sensor systems. One of these crucial parameters is the roll gap,which is investigated as part of the research project PIREF. In this paper an experimental setup for examining the roll gap during a rolling process is presented and based on these results different sensor arrangements are discussed.
Velocity Approximation of Hot Steel Rods Using Frequency Spectroscopy of the Cross-Section Area
(2019)
In this work, an approach for velocity approximation of hot steel rods based on frequency spectroscopy is presented. For this purpose, a sensor already implemented in a rolling mill for measuring the cross-sectional area of the rolling stock is used to obtain information about the velocity of the hot rods. Moreover, the effect of forward slip is briefly discussed.
Mobile Walzenmesstechnik
(2003)
In the field of magnetic inductance tomography,
signal processing is a real challenge. This is due to the divergent
nature of magnetic fields. The sensitivity, i.e. the change in the
receiving signal by means of an electrically conductive sample
in a measuring volume depends strongly on the positioning
of the sample. Objects that are located near the transmitting
or receiving coils are very well locatable, where objects in
larger distance are hard to detect. In this paper an approach
is presented that improves the topology of the magnetic fields
in the ”magnetic induction tomography” (MIT) by changing
geometric constructions and current patterns of coils so far,
as to allow a sharper localization of objects within the space.
The aim is to level the distribution of the sensitivity in the
measuring volume, so that electrically conductive objects with
a larger distance between transmitting and receiving unit can
be detected with almost the same signal intensity as objects
close to the transmitting and receiving unit. The simulation tool
Comsolic is used for the geometric modeling making a finite
element analysis (FEA). The subsequent signal processing and
analysis of the simulation results are implemented in Matlabic .
Within this FEA the coil geometries and current patterns are
changed numerically, so that the minimum object size, that is
still detectable, is, compared to the known MIT, reduced and the
sensitivity of the system is improved. To validate the simulation in
Comsolic , first simulation results are compared with analytical
models and analyses.