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The diameter of rebar has never been measured accurately. At this stage, the negative rate of rebar can only be controlled by manual experience, calipers, and weighing, which cannot maximize the negative rate.
Real-time, online detection provides a digital basis for negative differences. In the past, it could only rely on the experience of steel rolling workers.
DBM actively develops the "Smart Eyes" online differential system to measure the cross-sectional area and precise running length of rebar online in real time, convert it into meter weight, and provide real-time differential rate and changing trends.
Create profits for steel mills: Provide a trend of diameter increase to maximize the negative difference; eliminate out-of-tolerance; a small innovation in the direction of intelligence, providing a basis for direct delivery of hot billets.
Requirements for post-break elongation and weight negative deviation of coiled steel bars and straight steel bars after straightening | ||||
Steel bar grade | Elongation after break | Weight negative deviation (%) | ||
A(%) | 6～12mm | 14～20mm | 22～50mm | |
HPB235、HPB300 | ≥21 | ≤10 | － | － |
HRB335、HBRF335 | ≥16 | |||
HRB400、HBRF400 | ≥15 | ≤8 | ≤6 | ≤5 |
RRB400 | ≥13 | |||
HRB500、HBRF500 | ≥14 | |||
The rebar online meter weight difference equipment is a new complete set of equipment that integrates optical, mechanical, electrical, visual and computer communication to intelligently monitor the negative deviation of rebar. It is highly advanced, accurate and reliable.
This equipment monitors the data of base circle, rib, speed, and length of rebar running at high speed, and calculates the negative deviation of the material, thereby providing real-time data reference for the on-site production process.
For a bar factory with a capacity of 1 million tons, the negative balance increased by 0.2%, and the income increased by 2,000 tons x 3,500 yuan/ton = 7 million!
National standard | Maximum value | Median | Minimum value | Total |
Allowable deviation % | 5.0% | 0.0% | -5.0% |
|
Allowable diameter mm | 16.80 | 16.00 | 15.20 |
|
Yield ratio % | 20% | 60% | 20% |
|
Meter weight g | 345.63 | 940.49 | 282.93 | 1,569.06 |
A steel plant has a negative balance of % | -3.0% | -3.9% | -4.6% |
|
Allowable diameter mm | 15.52 | 15.38 | 15.26 |
|
Meter weight g | 294.97 | 868.56 | 285.32 | 1,448.85 |
HiSec Negative difference % | -3.7% | -4.2% | -4.7% |
|
Allowable diameter mm | 15.41 | 15.33 | 15.25 |
|
Meter weight g | 290.73 | 863.15 | 284.72 | 1,438.60 |
|
|
| Lose weight g | -10.25 |
Rebar mm | 16 |
| Weight reduction ratio | -0.71% |
Total output tons/year | 1,000,000 |
| Total weight loss tons | -7,128 |
Steel price yuan/ton | 3,500 |
| Income | -24,947,645 |
Provides an increasing trend in diameter to maximize the negative difference
The system uses online cross-sectional size detection + high-precision speed and length measurement + big data to monitor the meter weight of the bar online. Through data cleaning, temperature compensation, sample database and big data analysis, the theoretical comprehensive negative deviation of the rebar can be detected online. To maximize the negative tolerance rate, if successful, the reduction can be adjusted in time to control the negative tolerance of the product, improve the product yield, and improve the negative tolerance stability rate.
The online cross-sectional size inspection equipment uses the CCD camera imaging method for measurement. The CCD imaging method refers to a method in which the object to be measured is placed in the object-space telecentric optical path system for imaging, and the CCD chip at the imaging position is used to receive the imaging information for size measurement. There are two main advantages of this measurement method: first, the imaging boundary is clear, the photoelectric signal can be accurate to 1 pixel on the CCD chip, and the measurement accuracy is high; second, the measured object is in the telecentric optical path of the object (i.e. parallel light When moving along the axial or radial direction of the probe in the field of view, the size of the image remains unchanged, which is conducive to high-precision measurement.
The speed measurement of the ultra-high frequency and high-precision speed and length measurement system uses the differential Doppler principle. The speed meter adopts spatial filtering technology and uses LED (light-emitting diode) light sources and CCD chips to achieve linear velocity measurement of space luminous particles.
Variety: Threaded bars, threaded high wire, round steel
Specifications: 5mm – 80mm. Covers 12-40 threaded rods
Rolling speed: maximum 120m/s
Object diameter(mm)：φ12～φ40
Allowable deviation(mm)：
Measuring rebar ≤± 0.06
(Rebar base circle, longitudinal rib, transverse rib)
Minimum measuring speed(m/min): 0
Maximum measurement speed(m/min): 20000
unit of measurement：m/s,m/min,ft/s
Accuracy: Better than 0.05%
Multiple cutting accuracy: ≤100mm
Working principle: When the rolling stock passes through the magnetic field generated by the alternating current, eddy currents are generated on the surface of the steel piece. The detection equipment converts it into an electrical signal. By analyzing the changes in the electrical signal, the cross section of the rolling stock is obtained, and then the negative error rate and its change are obtained. trend.
Equipment accuracy: ±0.5% of cross-sectional diameter, or ±1% of meter weight
AC 220±15% ，50Hz AC 380±15% ，50Hz
There should be no dust, water mist, vibration (vibration of the shears, if the vibration is too large, it may need to be added (guides, pinch rollers)
Main equipment： -40～50 Terminal industrial computer： 0～35
Precision photoelectric equipment, water and water mist are strictly prohibited; Waterproof sealing measures should be taken near the equipment
Installation location: the equipment is installed after the high bar reducer, and before double-length shearing, a high-speed photoelectric camera measurement system with eight sets of fixed measuring heads is used to measure the outer contour size and length of the passed rolled material in real time online.
Dust removal purge gas: comes with fan and filter
Rebar purge gas: pressure 0.4~0.5MPa; flow rate 3m3/min
Environmental requirements: water and water mist are strictly prohibited for precision photoelectric equipment.
Installation method: hoisting.
Fan installation: Keep away from environments with concentrated dust and high temperatures. The connection of the fan coil should be smooth and bending is strictly prohibited.
Confirm that the measuring vehicle is online and the high-pressure blower is turned on. Click the "Start Measurement" button to measure the system. The display screen can be switched during measurement status
Confirm that the circuit of the measuring equipment is in normal use, the mirror is 1000mm away from the middle of the bar surface, and the middle position of the bar is irradiated vertically
When replacing rolling stock with different diameters or equipment maintenance,Regularly or irregularly. During the production process, when rolling bars of different specifications, it is recommended to use standard bars in the corresponding specification range for calibration.
When changing specifications, it is necessary to ensure that the length of the bar measured by the equipment is basically consistent with the actual length of the bar, and that the bar does not jump significantly in the roller table.
The maintenance interval for window lenses is approximately 20 days. During maintenance, remove the sealing ring on the online size inspection equipment, wipe the window lens clean with a lens wiper, and then reinstall the sealing ring.
Make sure the water-cooling and air-cooling equipment are working properly, and confirm that the circuits are normal.
Fan filter element maintenance intervals are 3 to 4 weeks (depending on site conditions). During maintenance, take the filter element out of the filter housing and gently drop it on the ground or use a compressed air duct to clean the dust on the filter element.
The maintenance cycle is about 20 days. Disassemble the water cooler casing and use an air gun to clean the air conditioning filter element and remove the dust.
Determined by on-site environmental factors, dust on the equipment should be cleaned regularly.
The industrial computer placed in the main control room must be turned on, the program is running, and the communication is normal during use.
The control cabinet placed in the power distribution room must be in running state at all times and the relevant parameters must be normal.
The industrial control is placed in the power distribution room to ensure that it is in running status at all times and the monitoring program runs normally.