One-stop intelligent solutions for steelmaking/continuous casting/steel rolling

ONLINE MEASUREMENT SYSTEM

Widely used in rolling steel, cast pipe, cable, glass pipe, plastic pipe, rubber roller, machining, chemical industry, food and many other fields

Intelligent online diameter gauge, hot rolling, Measurement accuracy reaches 300μm! Radar technology
steel rolling, online diameter gauge, ONLINE MEASUREMENT SYSTEM

steel industry measuring systems

The measuring instruments produced by DBM mainly include high-precision intelligent wire online callipers, bar online callipers, variable large diameter online callipers, special callipers for threaded steel/bolt steel, angle steel/square steel measuring instrument, Steel plate/flat steel width gauge, plate width gauge, laser thickness gauge, ray thickness gauge, inner hole straightness detector, fork diameter gauge, etc., and intelligent measurement terminals that can be used flexibly.

Real-time online accurate measurement of speed and length. ( bars, tubes, wires, plates, strips, hot rolling, cold rolling, etc.)

Applied to online detection of the size of wires and bars at high and low-speed rolling lines, (inner and outer diameter, longitudinal and transverse rib, etc.) of round steel bar and rebar.

Simultaneously measures the width and thickness of flat steel or steel plate in real time. Used for cold or hot-rolled flat steel, and other plate steels.

Suitable for slitting and rolling production lines. Used for three-slit, four-slit and five-slit rolling

Used for outer diameter detection of low-temperature rolled pipes, straight seam welded pipes, cold-drawn bars, silver bright bars, rubber pipes, plastic pipes, wires, cables, etc.

Surface defect monitoring of rolled steel, non-ferrous metals, etc. Applicable to any shape of profile, such as round, square, rebar, hexagonal, rail beam, T-shaped, H-shaped, etc.

Applied to measure various hole types such as round holes, square holes, and hexagonal holes. Used for wire drawing dies and cable dies that require accurate measurement of inner holes.

Mainly used for diameter and straightness detection of metal rods, pipes, ceramic pipes and other products

Customized products

Customized products

Based on strong technical strength and the most advanced sensor technology today, DBM professionally undertakes various non-standard measuring instruments

With machine vision as the core, DBM can provide intelligent equipment R&D, manufacturing and transformation services such as unmanned factories in the metallurgical industry and other industries, machine vision, and robot application design.

Product menus

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steel industry measuring systems

DBM has developed multiple series of products integrating optical, mechanical, electrical and computer applications, such as large-scale online photoelectric diameter gauges, online photoelectric width gauges, online straightness gauges, a series of small photoelectric diameter gauges, laser thickness gauges, etc.

Independent R&D and Production

The measurement accuracy is above 0.003mm, the measurement frequency is 500-2000 Hz, and the maximum measurement range is above 1500mm

personalized configuration

The intelligent measurement and control platform can realize personalized configuration according to the different needs of customers

Advantages and highlights of DBM intelligent measuring instrument

1. Measuring instrument technical advantages

1) Performance characteristics of the diameter measuring instrument

(1) The measurement is accurate, and the dynamic error of measuring round steel is not greater than 0.01mm. The dynamic error of the rebar is not more than 0.06mm.

(2) The unique jitter error elimination technology completely eliminates the measurement error caused by the jitter of the rolling material.

(3) All-digital high-frequency measurement system, the measurement frequency is up to 2000Hz, that is, 2000 rolled sections are measured per second

(4) It can detect the common defects of round steel, such as: “ear”, “wrong roll”, etc.

(5) Measurement data alarm function.

(6) Historical data queries can be provided.

2) High precision, calibration-free

The DBM calliper adopts a strictly designed and calculated optical path system with clear imaging boundaries. And the whole series of products are adjusted according to the accuracy of 3 microns, reaching the international leading level of large-diameter measuring instruments. During normal use, the calliper is free from calibration for all dimensions within the range, providing users with unprecedented convenience.

3) Provide an external database

In addition to the storage and analysis functions of the measurement data, the software also provides an external database, which is convenient for users to process, organize, analyze, calculate, and count the measurement data according to their own needs.

4) Strong defect detection capability

The software has the ability to detect the wrong roll, ear, head defect length and tail defect length of the bar, providing strong quality support for actual production.

5) Excellent protection performance

The calliper is designed according to the protection level of IP54 to prevent dust from entering, prevent splashing water from entering, resist high temperatures, resist electromagnetic interference, and adapt to harsh operating environments.

6) Independent steel guide

It is recommended to use an independent steel guide for this equipment and use the rolling line guide trough directly, and the steel passing parts are neither connected nor contacted with the calliper. The impact and vibration of the steel guide groove will not affect the calliper, which reduces the factors that cause the calliper to fail and saves the purchase and management costs of the special guide groove.

7) High-brightness LED light source

The LED light source imported from the United States equipped with the measuring head of DBM calliper has high brightness, long life and strong temperature adaptability.

★ The highest brightness can reach 3000mcd. Even in the case of slight dust pollution on the window lens, the diameter measurement is normal, which prolongs the maintenance cycle of the diameter measurement instrument;

★ The normal service life is more than 80,000 hours;

★ The ambient temperature -20℃~50℃ can be used normally, and the environmental adaptability is better than that of the laser lens.

8) High-frequency measurement

The scanning frequency of the calliper depends on two conditions: one is the CCD chip with high scanning frequency; the other is the digital signal acquisition system. The DBM calliper adopts a new high-frequency linear array CCD chip with a scanning frequency of 15MHz, combined with the fully digital signal acquisition system independently developed by the company, and the sampling frequency can reach 1000Hz

sampling interval

Advantages of high-frequency measurement: When measuring high-speed rolling products, the higher the measurement frequency, the smaller the interval between measurement points, and the higher the probability of detecting product defects. As shown in Figure 2.1, it is assumed that the rolling speed of the rolled material is 100m/s, and there are 6 defect points within each meter. When the measurement frequency is 100Hz, at most one defect point can be detected per meter; when the measurement frequency is 2000Hz, it is possible to detect multiple defect points within 1 meter.

9) Industrial computer calculation, stable performance

At present, the data processing method of most manufacturers’ diameter measuring instruments is that the single-chip computer calculates the final result, and then transmits it to the industrial computer for post-processing. Such a circuit system has poor adaptability to the environment of high temperature, high dust, and strong electromagnetic interference at the steel rolling site. In order to improve the environmental adaptability and performance stability of the calliper, Lanpeng has developed a circuit system that directly transmits the collected raw data to the industrial computer for calculation. The adaptability of the calliper to the field environment is improved, and the operation stability of the whole set of equipment is greatly improved.

10) Techniques for Eliminating Jitter Errors

In the calliper industry, the measurement error caused by the jitter of the measured object has always been a problem that plagues the technicians in the industry, and other manufacturers have not solved it so far. After painstaking research, our company took the lead in solving this problem in the industry by adopting multiple synchronization technologies such as light source-signal acquisition unit pulse synchronization, multi-channel acquisition synchronization, signal acquisition-communication transmission synchronization, etc. It eliminates the jitter error and fills the gap in domestic technology.

11) The LED display is large and full of functions

The on-site LED display screen configured by Lanpeng Caliper has an overall size of 1550mm×1070mm, a data word height of about 150mm, and a visual distance of more than 30m, which is convenient for on-site operators to monitor in time. The LED display screen has an on-site alarm function. The specific alarm method is: when the three detection index values ​​of the tested rolled material are within the normal range, the font of the index will be displayed as “green”. When one or more detection index values of the tested rolled material are in the upper tolerance, the value of the corresponding indicator will change to “red”, and the running status will be displayed as red “out of tolerance”; When the value of one or more detection indicators is in the lower limit, the value of the corresponding indicator will turn “yellow”, and the operation status will be displayed in red “out of tolerance”.

12) Easy maintenance

There are only two daily maintenance items for this set of equipment, namely, the wiping of the window lens and the cleaning of the fan filter element. The maintenance cycle, maintenance method, and time of these two items are as follows:

★ The maintenance cycle of window lenses is about 20 days. During maintenance, remove the sealing ring on the caliper, wipe the window lens clean with a lens cleaning cloth, and then install the sealing ring. Lens maintenance only takes about 10 minutes once.

★ The maintenance cycle of the fan filter element is 1 to 2 weeks (depending on the site environment). During maintenance, take out the filter element from the filter housing, drop it lightly on the ground, or use a compressed air duct to clean the dust on the filter element. Maintenance takes no more than 10 minutes.

★ Open the door for maintenance, easy to clean and wipe the lens, and the operation is more convenient.

The measuring instrument adopts the smart workshop IoT sensor data acquisition system

In the industrial Internet of Things scenario, the workshop needs to transmit the data collected by the equipment sensors to the central control system in real-time through the network, to perform real-time monitoring and predictive maintenance on the working environment, product status, and equipment operation. Therefore, it is not difficult to see that the collection of sensor information has also played a great role in the development and promotion of the industry.

In addition, we can also transmit the workshop data in the form of modules to the higher-level MES system and ERP system through various Internet of Things platforms and various protocols, to facilitate the overall management and operation of the enterprise, so that the scale of the enterprise Real-time management of growth and products, enhanced stability requirements, and reduced operation and maintenance costs.

Through the information management of the production process, the modified system can realize the visual management of the production plan, visual management of the production process, visual management of equipment status, and visual management of the assembly process, thereby reducing the cost of equipment and material management, and reducing the transmission of equipment information and management information waste, thereby improving product quality, reducing defective products, and providing a strong impetus for the company to pursue cost reduction, eliminate defective products, pursue zero inventory, and pursue comprehensive, efficient, flexible and high-quality services.

Based on such advantages, everyone can’t help but wonder: How is the workshop IoT sensor data acquisition system constructed, and what are its specific data links and operation steps? Next, let’s take a look together.

 

Data link transmission

date link

1/ Each measuring device converts the detection signal into digital information, assembles it into structured data, transmits it through the network, and finally reaches the display terminal.

display terminal

2/ The rule engine module of the acquisition system filters, enriches, and converts the raw data obtained by the sensor, outputs numbers, fluctuation graphs, histograms, etc. in real-time, and stores them in the database and local server in the review background.

3/ The server can back up the data to the cloud through the Internet, and display it to the control center and other end users.

 

Choose the right equipment and solutions

diameter measuring instrument

1. Sampling various product parameters and professional equipment in the workshop production line to determine various monitoring constants, width/thickness/diameter/length/height/section profiles, and other data. If you want to obtain some special values, you may also require custom special equipment.

2. Select the equipment, and the sensor monitoring data that is different from the data flow scheme of the configuration products mentioned above. What also needs to be considered is the specific development of the software terminal.

3. Carry out business development on the server, determine the required functions, determine the receipt of device data and issue control instructions.

4. The server program establishes a connection with the sensor, associates with the feedback terminal, and performs the overall joint debugging operation. The last point is related to the data reported by each device. It is also the most critical step. Professional staff must be installed and debugged.

DBM has independently developed a variety of photoelectric measurement systems. Hardware products such as diameter gauges, width gauges, thickness gauges, profile gauges, and straightness gauges can reach a maximum accuracy of 0.01mm, and independently developed DBM measurement and control 2.0 professional measurement and control The platform can provide customers with mature measurement and control solutions for metallurgical production lines in various scenarios, and contributes China’s strength to building smart production workshops in the steel industry.

 

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