Online Roughness Measurement Online Topography Measurement based on the Light Sectioning Principle
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1 Online Roughness Measurement Online Topography Measurement based on the Light Sectioning Principle Dr.-Ing. Wolfgang Bilstein, Amepa GmbH
2 Content Motivation Optical online roughness measurement Implementation Waviness measurement Online Combined roughness and oilfilm measurement Resumé
3 Motivation Significance of roughness and waviness for sheet surfaces Traditional roughness measurement Welf Schiefer: Mitfahrgelegenheit
4 Significance of roughness for sheet material High surface quality strips required due to: Complex metal forming Increase of productivity Paints will be applied without filler in the future Higher demands on surface finish (homogenious appearance for material mix of modern cars) Rising importance of topography measurement
5 Traditional measurement of roughness Mechanical stylus measurement: - Impossible on moving product - spot test at the end of a coil or - on sample in laboratory Ra 1 l l 0 z( x) dx
6 Optical roughness measurement online Different approaches to measure the roughness online Light sectioning principle Laboratory 3D scan examples with light sectioning (Waver and EBT)
7 Different approaches to measure the roughness online Relativ measuring principles: Scattering of light as measure of an optical roughness which can be correlated with the mechanical roughness Speckle analysis Absolut measuring principles Triangulation Deflectometry Light sectioning principle (2D Triangulation)
8 Necessary properties of an online system Absolute measurement as close as possible to stylus system by optical means Usable for all sheet surfaces and coatings Unaffected by production environment, e.g. speed, vibrations etc. Verifiable by user - not a black box High dynamics for process control High accuracy and good comparability to stylus results
9 Light Sectioning Principle 1. Laser line projected onto surface (here 45 ) 2. Imaging of distorted line with camera 3. Evaluation of line distortion gives a high resolution surface profile 4. Calculation of roughness parameters
10 Laboratory 3D scan with the light sectioning principle 3D depth maps (grayscale coded, ca. 1x1mm 2 ): a) Waver b) EBT textured hot dip galvanized steel sheet
11 Implementation Integration of the system into a rolling mill Example for an installation Online surface images Correlation with stylus measurement
12 Integration of the system into a rolling mill Trigger level Excentricity of roll Specifications: Magnification 6x FOV1200x400µm WD 28mm 20 (90) images/s Wavelength 905nm Pulse length 8ns
13 Example for an installation Installation in Feuerverzinkung (vmax = 180m/min) mit definierten Schutzbereichen
14 Online surface images a) Ra = 3.5µm b) Ra = 1.6µm c) Ra = 1.2µm Sheet surfaces: a) Annealed steel b) Hot dip galvanized (EBT texture) c) Electrogalvanized (EDT texture)
15 Correlation with stylus measurement a) Stylus operator vs. Stylus laboratory b) Stylus vs. optical online
16 Waviness measurement online Waviness measurement Wavisurf Laboratory results Online results Prozess optimization
17 Waviness Measurement Wavisurf System requirements: High speed camera (ca. 4kHz) Dynamische synchronization with strip speed Precise allignment of the optics
18 Laboratory results Comparison of mechanical stylus with optical waviness measurement (sample speed 60m/min)
19 Online results Comparison of mechanical stylus with optical waviness measurement (vmax = 240m/min)
20 Prozess optimization Evaluation and quantification of process parameters onto the waviness (hot dip galvanizing line)
21 Combination of roughness and oilfilm measurement Offline analysis of blanks Oil film distribution Roughness distribution
22 Prediction of deepdrawing behaviour Used by: Audi Daimler
23 Resumé SRM is the standard system for online-roughness measurement in Europe Benefit: Modelling of processes Process control Process optimization Product improvement Auditing Waviness measurement WMS: Extension of the roughness measuring system for the evaluation of waviness parameters (Wsa, Wa0.8 etc)
24 Thank you very much for your attention.
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