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For the rod shape measurement of hot rolled round steel bars (rods) the high frequency eddy current method is especially well suited as it requires no contact point and is not limited to below the Curie temperature. Defects of the rod's shape can be detected by measuring the impedance spectrum of the RLC-oscillator. In the first laboratory setup an Agilent impedance analyser was used for initial tests. Nevertheless, this setup cannot be applied in a steel plant due to the difficult environmental conditions. Hence, a vector network analyser for passive impedance measurement that is applicable in these surroundings was developed.
Methods of red-hot rod shape testing require a robust non-contact measurement principle as a touch point could lead to damages to the rod and the detection unit. Therefore a new basic approach based on high frequency eddy current (HFEC) has been investigated. Due to the robustness and the ability to determine the rod shape even above the Curie temperature this principle is especially well suited and can be implemented in the production process directly. The first automatic measurement setup was successfully developed with promising results. Hereby a defect of ovality was detected with a parallel RLC-oscillator. The capacity of this RLC-oscillator is constant whereas the inductance is the measurement part that varies due to eddy current interactions with the rod.
Untersuchung des Einflusses von Längsrissen in Drähten auf die Impedanz eines Wirbelstromsensors
(2012)
Influencing Parameters on Measuring the Cross-Section Area of Hot Rolled Rods in Steel Industries
(2014)
Optimization of Encircling Eddy Current Sensors for Online Monitoring of Hot Rolled Round Steel Bars
(2014)
Modern manufacturing industries are continually working on quality enhancements for the hot rolling process of round products. One method for improving the finalisation of the rods is the implementation of an automatic size control system. As a result of these trends over the last few years, there has been an increasing demand for more accurate online measurements. Thus the reason for the research performed for this thesis. A particular challenge throughout this research was dealing with the temperature changes (up to 1200°C) from the in- and output of the fervent rolling stocks, and the effect this temperature changes had on the sensors. Furthermore, there is also high demand for developing fast and practical electronic measuring equipment, capable of measuring during high transport velocities (up to 120 m/s). The eddy current principle is just one of the very few methods available which can with-stand such harsh industrial environments. In fact, eddy current sensors are already being integrated into online monitoring tasks for hot rolling processes. The measurement uncertainty, however, is still considerably large for process control purposes. One reason for this lies within the ability for eddy current detectors to receive signals influenced by outward forces, i.e. forces dependent on its location, its geometry, the outside temperature and the material properties of a particular target. Thus the current accuracy for a cross-sectional area measurement, for example, is no higher than 1%. As a result, this thesis investigates the magnitude of all individual influential factors on the eddy current detectors, using model-based analysis techniques. The analytical model provides a solution for all rotationally symmetrical targets and the FEA model covers all of the other influencing parameters in a more time consuming manner. This thesis then provides different methods which are developed to separate the cross-sectional area measurement of a rod from all of the other influencing parameters. In addition, a material tracking approach for round products is developed. Two different kinds of prototypes, capable of measuring approximately 466 Tons of red-hot steel rods during the production process, are finally introduced in this thesis. The usefulness of the eddy current principle is validated by the provided field test results. The count accuracy for the identification of 2876 bars was found to be 99.93%, and the average measurement accuracy for the cross-sectional area experiments was reduced to ± 0.29 % when including all of the findings.
Wirbelströme werden in der Mess- und Sensortechnik sehr erfolgreich benutzt, um berührungslos Risse und Abstände metallischer Halbzeuge zu bestimmen. Die Messung von Konturen ist mit diesem industrietauglichen Wirkprinzip bisher nicht realisiert worden. Hier werden häufig optische Messsysteme eingesetzt. Speziell bei glühenden Werkstücken oder bei Benetzung der Halbzeuge mit Bohremulsionen und Schneidölen steigt der Aufwand für den Einsatz optischer Systeme stark an. Messverfahren, die auf hochfrequenten Wirbelströmen basieren, sind aufgrund ihrer einfachen Aufbauten deutlich robuster und somit besser für diese Anwendung geeignet. Voruntersuchungen zeigten, dass mit dieser Methode schon kleine Geometrieabweichungen des Walzgutes von wenigen Mikrometern detektiert werden können. In diesem Beitrag werden zwei Möglichkeiten zur Messung der spektralen Impedanzbeeinflussung eines Messschwingkreises durch die Wirbelströme im Werkstück gegenübergestellt.