The WireProfiler is a multi axis non contact mill gauge providing high accuracy cross section profile and shape measurement on hot or cold wire rod or pig iron. High precision sensors are at the heart of the WireProfiler but to ensure an accurate system the design details of all the supporting components and equipment need to be carefully considered. This is where LIMAB’s experience counts by paying close attention to the overall design. Furthermore, the WireProfiler uses our patented algorithm that eliminates errors due to bar movement in the measurement field.

Measurement System

The WireProfiler is an non oscillating profile measurement system designed for in-line measurement of products in wire rod  mills. The system measures on hot or cold rolled material passing through the gauge and present measurement in 2D and 3D graphs as well as numerical values of key figures. 

Measuring method

The WireProfiler uses up to 6 high performance laser micrometers, each one scanning at 1200 Hz making it the fastest rod mill gauge available today. The true cross section shape is determined by measuring at 12 points around the circumference of the rod. LIMAB’s patented software algorithm ensures that movement and vibration of the wire in the measuring field do not affect the measuring accuracy. This method precisely measurers the cross section profile and instantly alerts operators to all common rolling mill shape errors such as under fill and overfill, roll misalignment and roll eccentricity. A pyrometer is incorporated which provides a very helpful temperature profile map along the length of the rod and is also used in the hot to cold size correction. Operator workstation displays can be located at up to 10 separate locations around the mill simply by connecting to the existing company network. A large digit remote display shows key measured values.

Applications

Several models for different sizes:
Round wire rod and rebars from Ø 1mm to Ø 150mm

Software

The software is designed for client/server mode. Several clients can be connected to one server. The server software collects data from the measurement system and handles communication with 2nd level systems. The client software calculates and displays the shape of the measured product graphically with cursors for max/min and two selectable cursors. Trend graphs show key dimensions over the length of the product. Numerical values display key figures of the product and the material temperature as well as the temperature inside the measurement frame. Nominal data from the 2nd level system is also presented. Hot measurement data is converted to cold data.

Benefits

Full cross section shape measurement using high performance laser micrometers which measures up to 12 points around the circumference of the wire.

Continuous through coil measurement and tolerance monitoring eliminates production of out of specification material increasing mill yield and reducing scrap.

Mill setup time dramatically reduced between product changes, eliminating need for cutting and measuring of samples.