621.3 Elektrotechnik, Elektronik
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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.
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.
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.
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.
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.
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.
A Large and Quick Induction Field Scanner for Examining the Interior of Extended Objects or Humans
(2017)
This study describes the techniques and signal properties of a large, powerful, and linear-scanning 1.5 MHz induction field scanner. The mechanical system is capable of quickly reading the volume of relative large objects, e.g., a test person. The general approach mirrors Magnetic Induction Tomography (MIT), but the details differ considerably from currently-described MIT systems: the setup is asymmetrical, and it operates in gradiometric modalities, either with coaxial excitation with destructive interference or with a single excitation loop and tilted receivers. Following this approach, the primary signals were almost completely nulled, and test objects' real or imaginary imprint was obtained directly. The coaxial gradiometer appeared advantageous: exposure to strong fields was reduced due to destructive interference. Meanwhile, the signals included enhanced components at higher spatial frequencies, thereby obtaining a gradually improved capability for localization. For robust signals, the excitation field can be powered towards the rated limits of human exposure to time-varying magnetic fields. Repeated measurements assessed the important signal integrity, which is affected by the scanner´s imperfections, particularly any motions or respiratory changes in living beings during or between repeated scans. The currently achieved and overall figure of merit for artifacts was 58 dB for inanimate test objects and 44 dB for a test person. Both numbers should be understood as worst case levels: a repeated scan with intermediate breathing and drift/dislocations requires 50 seconds, whereas a single measurement (with respiratory arrest) takes only about 5 seconds.
This experimental study demonstrates for the first time a solid-state circuitry and design for a simple compact copper coil (without an additional bulky permanent magnet or bulky electromagnet) as a contactless electromagnetic acoustic transducer (EMAT) for pulse echo operation at MHz frequencies. A pulsed ultrasound emission into a metallic test object is electromagnetically excited by
an intense MHz burst at up to 500 A through the 0.15 mm filaments of the transducer. Immediately thereafter, a smoother and quasi “DC-like” current of 100 A is applied for about 1 ms and allows an
echo detection. The ultrasonic pulse echo operation for a simple, compact, non-contacting copper coil is new. Application scenarios for compact transducer techniques include very narrow and
hostile environments, in which, e.g., quickly moving metal parts must be tested with only one, non-contacting ultrasound shot. The small transducer coil can be operated remotely with a cable
connection, separate from the much bulkier supply circuitry. Several options for more technical and fundamental progress are discussed.