TubeProfiler 3D – Measurements of the dimension and true shape of tubes

The LIMAB TubeProfiler 3D system measures the outer dimensions and true shape of tubes. The system can be installed in both cold and hot tube rolling applications. The TubeProfiler 3D integrates a selective number of sensors for an accurate measurement of the true cross section of the produced product with full 360° coverage of the circumference. The TubeProfiler 3D system has proven its reliability among several of the top quality steel tube 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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TubeProfiler 3D

Basic Specification

Tube ShapesTube Dimension (mm)Tube Dimension (inch)Tube Temperature
Allup to 1600up to 650-1200°C / 32-2200°F
Larger dimensions on request

Operating Principle
The TubeProfiler 3D integrates a selectable number of LIMAB ProfiCura 2D laser sensors. The ProfiCura 2D sensors are based on laser triangulation technology and in the TubeProfiler 3D system these sensors are mounted on a base plate around the object to be measured. Due to this technology the projected laser line covers 360º of the circumference.

Applications

  • Full profile and dimensional measurements of hot and cold rolled tubes
  • Process applications as for example piercing mill, stretch-reducing mill, sizing-mill, forming and welding line, exit of a Kocks block and finishing line
  • Final inspection and NDT-area 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 tube. This feature gives the possibility to rapidly detect rolling mill problems like eccentric or damaged rolls.

Calibration
The TubeProfiler 3D is delivered with a calibration tool for the system calibration. The calibration procedure takes 10-15 minutes to perform.

Automatic height adjustment
The TubeProfiler 3D will automatically adjust its height position so that the pass-line of the tube always will be centered in the gauge, independently of the tube dimension.

Maintenance position
The TubeProfiler 3D 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 TubeProfiler 3D 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 TubeProfiler 3D 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 tubes 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 TubeProfiler 3D system, the true shape of the tube 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 tubes before correct size.

Time saving
Avoids time consuming manual inspections of tubes by the operators.

Improved Safety
Eliminates hazardous manual inspection of hot tubes by operators.

Rugged design
The TubeProfiler 3D 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 TubeProfiler 3D integrates our own produced state-of-the-art sensor, the ProfiCura 2D. The ProfiCura 2D 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.

Weld Measurement
Implementing an additional ProfiCura 2D gives the possibility to measure the weld width and height where it is applicable. Values can be included or excluded from tube OD.

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

Round – Square – Rectangle

Tube ShapesTube Dimensions (mm)Tube Dimensions (inch)Tube Temperature
Allup to 1600up to 640-1.200°C / 32-2,200°F
Larger dimensions on request
Number of laser sensorsTo be defined depending on material dimensions
Sensor measurement rate From 240 (Hz)
Cooling air 2.000 (m³/h)
Cooling air temperature in gauge+10 to +30°C (50 - 86°F)
Gauge dimensions (HxWxL), from 2000 (H) x 1700 (W) x 600 (L) (79 x 67 x 24”)
Electrical power requirements 230 VAC, 50Hz, 16A or 120VAC, 60 Hz