Steel Inspection

 

JLI Steelworks Inspection Systems are custom designed turnkey solutions for measuring dimensions, shapes, surface defects and flatness.

The systems cover a wide range of production processes both hot and cold. All equipment is designed for the actual environment. This can include water cooled and air blown camera housings suitable for operation at temperatures exceeding 200oC.

General features/benefits of JLI turnkey systems include:

  • Custom made
  • Adapted to existing production lines
  • Internet connection
  • Excellent reliability track records
  • Special applications

     

    Examples of Systems Commisioned by JLI

    Paint marking on a billet.Paint marking on a billet

    		  

    Character Reader 

    A single or multiple camera system can be trained to read dot or spray marking on steel products. Installed after the marking machine the system is used to verify the marking. At other points in the process the products will be automatically identified.

     

    • Single or multiple camera operation
    • Automatic reading
    • Flexible recognition rules
    • Verification of marking quality
    • Interface to Mill computer

    Plate Flatness pdf

    Plates cut to customer size are measured for flatness.The vision system is installed after the shear where the relative elevation of the surface is measured and a graphical map of flatness is produced. Plates outside specifications are detected.


    • Compact design, max. height 2 m
    • Accuracy better than 1 mm
    • Accept/reject signals to shear operator
    • Interface to Mill computer
    • ADSL connection for remote monitoring and control
    • Light system by standard street lighting: Life time > 3 years

    Flatness map of a plate.Flatness map of plate

    Camera location, 15 m from hot shear.Camera location, 15 m from the hot shear

     Bloom Cropping 

    The bloom cropping system covers the area at the shear and measures the distance from the shear to the end of the material. The system recognizes pointed ends or fishtails, and has several algorithms to recognize the extreme point of fishtails or eliminate git ends.

     

    • Single or dual camera
    • Automatic detection of arriving bloom and shear operation
    • Displays tailored for pulpit requirements
    • Interface to Mill computer
    • Automatic recording of discarded lengths with time and date

    Slab Gauge 

    The slab dimension systems are typically installed before the primary mill. At this location the system can be used to check the slab size before the fi rst pass.

    • Single camera operation
    • Camera installation away from the hot environment
    • Software to prevent false measurements due to steam
    • Fast continuous operation
    • Displays tailored for pulpit requirements
    • Interface to Mill computer
    • Remote control
    • Accuracy +/- 2mm

    Hot slab being measured.Hot slab being measured

    Typical bar.Typical bar

     

     

    Bar Length Gauge 

    The cameras are placed above the cooling bed on the outside of the roof. The system detects when the bar is moved from the roller lane to the walking beams. Reference marks are used for calibration in every measurement cycle.

     

    • Self calibrating
    • Easy access to the cameras also during production
    • Accuracy on a 100 m bar is 25 mm

    Slab Concast Measuring System pdf

    The speed and dimensions of concast steel are normally measured mechanically. The JLI system eliminates the contact wheel and manual measurement procedures. The accuracy is 0.1% on speed, 0.5 mm on thickness and 2 mm on width. This data and information on specific gravity enable the steelworks to cut slabs to exact weight.

     

    • Non contact measurement in the harsh concast environment
    • Interface to Mill computer
    • Clamp signal based on weight calculations
    • Accuracy: 100 kg on a 20 tonne slab, all included

    Slab casting.Slab concasting

     

     

    Section profiling.Section profiling

    Section Profile

    Section profiles are measured using structured halogen lights and cameras. The system operates on hot or cold sections.

     

    • Instant precise measurement of profi les in the rolling process
    • No use of lasers and therefore no protection issues
    • Cooling water and scale disturbances are eliminated by software
    • Systems tailored for the individual steel mill requirements
    • Integration techniques for high precision measurements

     

    Link to reference publication (Iron Steel) 

    Brake Pad Inspection (TTinspect)

    Condition based control of brake pads on trains. Optimize the use of brake pads by monitoring the wear. Inspection unit consists of advanced lighting and up to 6 high resolution cameras. Save up to 15-25% compared to manuel inspection.

     

    • Unit installed trackside to increase frequency of real-time imaging
    • Accurately measures brakes from 0 to 100 mph
    • Strobe light source provides sharp images
    • Units protected from the environment with air pressure hose ensuring a constantly clean lens
    • Quick release coupling for trackside maintenance with no interference to service

    Link to reference publication (DANISH). 

    Sample images of brake pad inspection 2 3 4 5 6 7 8 

    Brake pad inspection unit.Brake pad inspection unit

    Classic rails.Classic rails

    Rail Surface Inspection 

    Moving at up to 4 m/s and in the hot end. Rails can be surface inspected and characters read. Using optical filtering images are enhanced making
    the rail visually appear as cold. As the rail enters
    the camera ring, images from up to 7 cameras are
    recorded.

    • Stand alone unit
    • Inspection performed at the hot-end, < 900o C
    • Replaces physical sample inspection
    • 360 inspection - no turn mechanism needed
    • Instant detection of errors down to 1 mm
    • Automatic detection of reoccurring defects

    Link to reference publication (Iron Steel) 

    Sample images of rail inspection 2