HotProfiler – Measurements of the true shape of bars

The LIMAB HotProfiler system measures the outer diameter, ovality and true shape of bars, blooms and billets. The system can be installed in both cold and hot rolling applications. The HotProfiler integrates up to 24 sensors for an accurate measurement of the true cross section of the produced product. The HotProfiler system has proven its reliability among several of the top quality steel bar producers in the world and gives instant feedback to the operators in order to reduce the mill set-up time and improve the production yield.

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Basic Specification

Bar ShapesBar Dimension mmBar Dimension (inch)Bar Temperature
Round20-3000.8-120-1200°C / 32-2200°F
Squares20-2500.8-100-1200°C / 32-2200°F
Rectangulars/Flats5..250 x 30..2500.2-10 ×1.2-100-1200°C / 32-2200°F
Hexagonal 20-3000.8-120-1200°C / 32-2200°F

Operating Principle
The HotProfiler integrates up to 24 LIMAB PreciCura 1D laser sensors. The PreciCura sensors are based on laser triangulation technology and in the HotProfiler system these sensors are mounted on a wheel which is rotated around the object to be measured. The HotProfiler has a patented and integrated movement compensation algorithm, which makes the measurement accuracy unaffected by vibrations and other movements of the bar.

Applications

  • Full profile measurements of hot and cold rolled round, square, rectangular and hex bars, blooms and billets
  • Process applications as for example exit of a Kocks block
  • Final inspection for quality assurance

Measuring diameter, ovality, shape and length
In addition to measuring the diameter and the ovality of the tube, the true profile is also accurately measured. As an option there is also the possibility to implement a length measurement using a Doppler velocimeter. The system provides valuable feedback to the overall performance of the tube rolling.

Software
The system provides easy to read real time 2D and 3D profile graphs, numerical values with warning and out-of-tolerance limits indicated so that the operators instantly can see where process issues are developing.

The software is designed for client/server mode with the possibility of connecting up to 10 clients to one server. The client has an operator interface which displays the measurement results in numerical values, in different trend graphs, in 2D cross sections views as well as a 3D graphical view. All measured values are logged to a database, which makes it possible to replay all measurements for different post production analyses and claims. Network TCP/IP is provided to Level 2 and for remote support.

3D presentation
The operator interface includes a 3D presentation of the bar. This feature gives the possibility to rapidly detect rolling mill problems like eccentric or damaged rolls.

3-roll measurements
The HotProfiler measures and communicates all key dimensions, such as GT/DT values, for optimization of rolling lines with 3-roll system

True profile measurements
Diameter measurements of bars have traditionally been performed with cameras or laser micrometer shadow gauges. These type of systems will only perform a correct measurement of the maximum dimension of the object. Shape irregularities like under- and overfills cannot truly be measured. With the HotProfiler system, the true shape of the bar will be measured with high accuracy and good repeatability.

Patented movement compensation
During rolling and transportation, the bar will vibrate and also make random movements. To eliminate measuring errors due to these movements, LIMAB has developed an algorithm that ensures reliable measurement irrespective of the material presentation.

End user certificates
Automatically generates end user certificate via level 2, containing measured key values of each individual tube.

Calibration
The HotProfiler is delivered with a calibration tool for the system calibration. The calibration procedure takes 10-15 minutes to perform

Automatic height adjustment
The HotProfiler will automatically adjust its height position so that the pass-line of the bar always will be centered in the gauge, independently of the bar dimension

Maintenance position
The HotProfiler can be equipped with a sliding table on rails which makes it possible to take the system out of the production line for maintenance and calibration

Forced air cooling
The HotProfiler is delivered with a forced air cooling system that makes installation simple, reduces the running costs and keeps the internal temperature of the gauge stable. In addition the air is used to keep the optics clean eliminating regular maintenance.

Turn-key solution
LIMAB can provide a complete turn-key solution. The HotProfiler includes all hardware, LIMAB-made sensors and software needed for any mill installation. LIMAB provides commissioning, training and on-going product support and service.

True profile measurements
Diameter measurements of bars have traditionally been performed with cameras or laser micrometer shadow gauges. These type of systems will only perform a correct measurement of the maximum dimension of the object. Shape irregularities like under- and overfills as well as corner radiuses and concavity/convexity cannot truly be measured. With the HotProfiler system, the true shape of the bar, bloom and billet will be measured with high accuracy and good repeatability.

Full cross section
Complete 360° scanning of the circumference.

Mill setup time reduced
Mill setup time at product change dramatically reduced. Less number of test bars before correct size.

Improved safety
Eliminates hazardous manual inspection of hot bars by operators

Software 3 point rollers
Software module to provide GT/DT values at exit of Kocks block

Rugged design
The HotProfiler is designed for the harsh environment in a steel mill, which includes a careful selection of the gauge material, effective air-purging and cooling.

LIMAB produced laser sensors
LIMAB has been developing laser based, optical triangulation sensors for more than 30 years. The HotProfiler integrates our own produced state-of-the-art sensor, the PreciCura. The PreciCura is a robust and very accurate sensor, available in several versions depending on the application. It is also stocked at LIMAB for fast spare part delivery.

End user certificates
Automatically generates end user certificate via level 2, containing measured key values of each individual bar.

Bar size range
Round20-300 mm / 0.8-12”
Square20-300 mm / 0.8-10”
Hex bar20-300 mm / 0.8-10”
Rectangles/Flats 5..250 x 30..250 mm / 0.2-10 x 1.2-10”
Larger sizes available on request
Number of laser sensors8 – 24
Sensor measurement rate 2000 (Hz)
Cooling air 2000 (m³/h)
Cooling air temperature 10-30 (°C) (50 - 86°F)
Gauge dimensions 2000 (H) x 1700 (W) x 600 (L) (79 x 67 x 24”)
Electrical power requirements 230 VAC, 50Hz, 16A or 120VAC, 60 Hz)