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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.
The development of innovative measuring technology for process optimization in hot rolling mills becomes more and more relevant because of increasing demands on product quality. Measurement technology for high-resolution non-contact cross-sectional area measurement has shown that the variation in cross-sectional area contains information about the rolling process. This information can be used for the development of new measurement devices and analytical methods for process optimization. The harsh environmental conditions and strict safety regulations result in great effort when implementing a new sensor prototype in hot rolling mills. For this reason, this work presents a mechatronic test stand that can simulate the cross-sectional area variation under laboratory conditions realistically.
Mobile Walzenmesstechnik
(2003)
Die transurethrale Resektion der Prostata (TUR-P) ist der Gold Standard für die endoskopisch-chirurgische Behandlung der Benignen Prostatahyperplasie (BPH). Unbekannt ist jedoch, ob bei der bipolaren TUR-P die Möglichkeit von elektrothermischen Verletzung von benachbar-
tem nichtopertiertem Gewebe besteht. Grund hierfür könnten höhere Ausgangsleistungen der Chirurgie-Generatoren sein. Deshalb werden experimentell gemessene Werte der räumlichen Verlustleistungsdichte um ein bipolares Resektoskop als Quellterm für die Berechnung der Temperaturänderung im operationsnahen Gewebe verwendet. Die Temperaturberechnung basiert auf der numerischen Lösung der Wärmeleitungsgleichung nach Penne. Für die gewählten Randbedingungen und Eingabeparameter sind keine signifikanten Temperaturerhöhungen im Berechnungsgebiet am proximalen Ende des Resektoskop-Schaftes festzustellen. Um ein umfassendes Verständnis zu gewinnen sollen weiterführende Untersuchungen mit einer Variation der Randbedingungen und Eingabeparameter durchgeführt werden.
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.
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.
Fat content of liver is an essential parameter to decide whether a liver is suitable for transplantation or not. The determination of fat content is often challenging and usually there is not enough time to bring a specimen to a pathologic laboratory. That is why transplantation clinics need a technique to measure the fat content of a graft. In this paper the theoretical basics and an existing laboratory setup are presented.
The harmonic and interharmonic analysis recommendations are contained in the latest International Electrotechnical Commission (IEC) standards on power quality. Measurement and analysis experiences have shown that great difficulties arise in the interharmonics detection and measurement with acceptable levels of accuracy. In this paper, the spectral leakage problems of the discrete Fourier transform due to synchronization errors of interharmonics are analyzed. The time-domain averaging is investigated for the processing of harmonics in the framework of the IEC standards. A difference filter is proposed to detect interharmonics and can be compatible with the IEC standards. Simulations and the field results show the usefulness of the proposed methods.
The transurethral resection (TUR) is a standard technique in urological treatment procedures. Both, monopolar and bipolar electrosurgical systems, are used for TUR. Whereas electrical and physical processes in surgery surroundings are well understood for monopolar systems, there is no sufficient data base for the assessment of the processes with the use of bipolar systems. In this context a multi-electrode measuring system was developed to visualize the spatial potential distribution around bipolar electrosurgical devices as a first step to risk analysis. To simulate the anatomic surroundings of a transurethral surgery a cylinder filled with isotonic saline solution was used as a complexity reduced experimental environment.
The bipolar transurethral resection is a further development of monopolar transurethral resection, being the gold standard in surgical treatment of prostate and bladder diseases. To create the metrological basis for understanding of electrical and physical processes during bipolar transurethral resection an experimental set-up to visualize spatial potential distribution around bipolar devices was developed. A hardware based signal conditioning and specific undersampling are presented as data acquisition methods for a sampling rate up to 1 MS/s. These methods are compared with the possibilities of a high speed data acquisition card. For more than four measuring channels and depending on the output bandwidth of the electrosurgical generator either hardware based signal conditioning or specific undersampling is suggested.
Bipolar electrosurgical systems are used for the treatment of benign prostatic hyperplasia (BPH) in urology. In order to analyse electrothermal processes during surgery the power loss density distribution around a bipolar resectoscope is calculated out of the measured potential distribution in isotonic saline solution ex situ. During further analysis power loss density values act as input for the Penne's bioheat equation. To achieve results, which are as realistic as possible, a method to obtain power loss density values, depending on the observed tissue or medium in the operating field, is presented. Applying this method, the power loss density distribution in isotonic saline solution at 25 °C is compared to the distribution calculated for the average conductivity of biological tissue in the region of interest.
Untersuchung des Einflusses von Längsrissen in Drähten auf die Impedanz eines Wirbelstromsensors
(2012)
Induktive Bioimpedanzmessung – Verbesserte örtliche Auflösung durch geeignete Spulengeometrien
(2013)
Influencing Parameters on Measuring the Cross-Section Area of Hot Rolled Rods in Steel Industries
(2014)
Die steigenden Anforderungen an den Umweltschutz bei möglichst niedrigen Kosten betreffen auch die öffentlichen Kanalnetze und Kläranlagen. Speziell die Kanalnetze sind über Jahrzehnte gewachsen, ohne dass kostengünstig eine genaue Bilanz ihrer Leistungsfähigkeit bis in ihre Segmente möglich war. Es fehlte vor allem in kleineren Systemen an Messwerten für die Transportmengen in Abhängigkeit der Witterung zur Beurteilung des Transportverhaltens der Einzelsegmente. Erst diese Messwerte ermöglichen eine mathematische Modellbildung mit Parametrierung und damit Ansätze für eine Optimierung. In diesem Beitrag wird der Prototyp eines neuartigen Sensors vorgestellt, der die gleichzeitige, kostengünstige und zeitbegrenzte Erfassung der Abwasserströme an verschiedenen Punkten im Kanalnetz ermöglichen soll. Die im Abwasserstrom befindlichen Teile des Sensors sind preiswerte mechanische Komponenten, die kostengünstig und einfach zu ersetzen sind. Die Erfassung der Strömungsgeschwindigkeit und der durchströmten Querschnittsfläche erfolgt mit Hilfe der sich an einem Störkörper einstellenden Druckverhältnisse.
In modernen Prüffeldern zur Warenendkontrolle dienen halbleitergesteuerte Frequenzumformer zur Einstellung der Drehzahl. Diese Systeme verursachen erhebliche Störungen der Strom- und Spannungssignale. Aus diesen Signalen müssen alle elektrischen Kenngrößen berechnet werden. Eine besondere Bedeutung haben dabei die Frequenz und Phasenlage. In diesem Beitrag wird ein mathematischer Algorithmus vorgestellt, der zur Berechnung von Frequenz und Phasenlage bei guter Unterdrückung dieser Störungen eingesetzt werden kann.
Im vorliegenden Beitrag wird das Phasen-Differenz-Verfahren zur Frequenzmessung der durch Rauschen gestörten Signale vorgestellt. Es wird gezeigt, dass Frequenzausreißer bei Anwendungen dieses Verfahrens entstehen, auch wenn das Signal-zu-Rausch-Verhältnis ausreichend groß ist. Die Ursachen der Frequenzausreißer werden analysiert. Zur Korrektur wird ein Lösungsansatz vorgeschlagen. Im Vergleich mit anderen Verfahren kann das verbesserte Phasen-Differenz-Verfahren die Frequenz der durch Rauschen gestörten Signale mit größerer Genauigkeit und vertretbarem Rechenaufwand berechnen.
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.
The production and deformation of perforated sheets introduces high levels of mechanical stress into the material. In a significant fraction, such stress levels lead to crack formation in the processed sheets. Additionally, the material might be thinned and weakened in the exposed areas; these areas tend to crack at any later dates. Currently no measuring device for the detection of such material cracks or narrowing in perforated sheet metals is in practical use. Such device should be able to test the deformed circumference of the processed sheets within the very limited time of the production cycles. This paper describes the physical principles and a metrological implementation of a potential method for fast crack detection in perforated sheet metals. Even a critical material thinning - prior to the formation of a crack - can be observed. The measuring task appears to be solvable on the basis of high frequency electromagnetic fields.
Die steigenden Anforderungen der fertigenden Industrie an Halbzeuge wie Stahl- und Aluminiumblech führen zu großen Anstrengungen bei der Entwicklung neuer und Verbesserung alter Walztechniken. Einen wesentlichen Einfluss auf die erreichbaren Flächentoleranzen der Bleche hat neben der Walzenform die Temperaturverteilung an der Walzenoberfläche.
Increasing demands from the manufacturing industry on semifinished products such as steel and aluminium plate are leading to greater efforts in the development of new and the improvement of existing rolling techniques. In addition to the shape of the roll, temperature distribution on the roll surface has a significant influence on the surface tolerances of the sheets which may be achieved.
The transurethral resection (TUR) is a standard technique in urological treatment procedures. Both, monopolar and bipolar electrosurgical systems, are used for TUR. Whereas electrical and physical processes in surgery surroundings are well understood for monopolar systems, there is no sufficient data base for the assessment of the processes with the use of bipolar systems. In this context a multi-electrode measuring system was developed to visualize the spatial potential distribution around bipolar electrosurgical devices as a first step to risk analysis. To simulate the anatomic surroundings of a transurethral surgery a cylinder filled with isotonic saline solution is used as a complexity reduced experimental environment. Investigations about time stability and a qualitative assessment of the experimental set-up show deviations of measured values less than 5%. This is sufficient for further analysis of calculated power loss density distributions based on measured potential distributions. The spatial potential distribution around a bipolar devices is presented by horizontal and vertical sections through the experimental environment.
Die transurethrale Resektion der Prostata (TUR-P) ist der Gold Standard für die endoskopisch-chirurgische Behandlung der Benignen Prostatahyperplasie (BPH). Unbekannt ist jedoch, ob bei der bipolaren TUR-P die Möglichkeit von elektrothermischen Verletzung von benachbartem nichtopertiertem Gewebe besteht. Grund hierfür könnten höhere Ausgangsleistungen der Chirurgie-Generatoren sein. Deshalb werden experimentell gemessene Werte der räumlichen Verlustleistungsdichte um ein bipolares Resektoskop als Quellterm für die Berechnung der Temperaturänderung im operationsnahen Gewebe verwendet. Die Temperaturberechnung basiert auf der numerischen Lösung der Wärmeleitungsgleichung nach Penne. Für die gewählten Randbedingungen und Eingabeparameter sind keine signifikanten Temperaturerhöhungen im Berechnungsgebiet am proximalen Ende des Resektoskop-Schaftes festzustellen. Um ein umfassendes Verständnis zu gewinnen sollen weiterführende Untersuchungen mit einer Variation der Randbedingungen und Eingabeparameter durchgeführt werden
In dieser Veröffentlichung wird ein Konzept vorgestellt, das es erlaubt die Topologie der Magnetfelder bei der „Magnetischen Induktionstomografie“ (MIT) durch geometrische Spulenkonstruktionen und Bestromungsmuster soweit zu verändern, um eine scharfe Lokalisierung von Objekten innerhalb des Raumes zu ermöglichen. Ziel ist dabei, die Empfindlichkeit im Messvolumen gleichmäßiger als in der bekannten MIT zu verteilen, sodass elektrisch leitfähige Objekte mit größerer Entfernung zwischen Sender- und Empfängereinheit mit nahezu gleich hoher Signalintensität detektiert werden können, wie Objekte in Sender- und Empfängernähe. Dabei soll die maximale Objektgröße, die noch zu detektieren ist, verkleinert und die Empfindlichkeit des Systems verbessert werden.
To analyze the electric field around bipolar resectoscopes, used in urology, in terms of reasons for late complications after a surgical treatment a flexible multielectrode system was developed to measure the 3-D potential distribution. A high spatial resolution is achieved with the least possible individual measurements under the conditions of a quasi-static electric field. A flexible arrangement and positioning of the measuring points in the vertical direction of the experimental environment enable an adjustable spatial resolution and the selection of the region of interest. The existing influence of the multielectrode system on the measuring results is described and a correction method is presented to achieve significant results. Thus, the multielectrode system is usable for a comparative study of bipolar resectoscopes varying in the arrangement of resection and return electrode.
Wirbelstromsensoren sind in der industriellen Messtechnik stark verbreitet. Insbesondere bei der Herstellung warmgewalzter Halbzeuge können sie durch ihre Robustheit gegenüber Wasserdampf und hohen Walzguttemperaturen überzeugen. Ein noch offenes Feld ist die In-Situ‐Detektion von Rissen im Draht während des Walzprozesses bei Walzgeschwindigkeiten bis zu 100 m/s und Materialtemperaturen bis zu 1200 ℃. Im Folgenden soll mittels der Finiten-Elemente-Analyse untersucht werden, wie sich Längsrisse im Draht auf Oberflächenströme und damit auf deren magnetische Flussdichte auswirken. Ziel ist es, Aussagen über den Einfluss verschiedener Rissbreiten und Risstiefen auf die magnetische Flussdichte zu machen und so einen möglichen Effekt auf einen Wirbelstromsensor untersuchen zu können.