TubeProfiler – Measurements of dimensions and true shape of tubes

The LIMAB TubeProfiler system measures the outer diameter, ovality and true shape of tubes and billets. The system can be installed in cold or hot rolling applications. The TubeProfiler integrates up to 24 sensors for an accurate measurement of the true cross section of the produced product. The TubeProfiler 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

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

Applications

  • Full profile measurements of hot or cold rolled round, square and rectangular tubes
  • Process applications, as for example, after piercing, stretch-reducing, sizing, forming, welding 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 a possibility to implement a length measurement using a Doppler velocimeter. The system provides valuable feedback to the overall performance of the tube rolling.

Patented movement compensation
During rolling and transportation, the tube 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.

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

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

Maintenance position
The TubeProfiler 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 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 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 ovality, flat-spots, under- and overfills as well as concavity/convexity cannot truly be measured. With the TubeProfiler system, the true shape of the tube will be measured with high accuracy and good repeatability.

Full cross section
Laser points are equally positioned around the complete 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 tube by the operators.

Improved Safety
Eliminates hazardous manual inspection of hot tubes by operators

Rugged design
The TubeProfiler 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 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 tube.

Round – Square – Rectangle

Tube ShapesTube Dimensions (mm)Tube Dimensions (inch)Tube Temperature
Allup to 1600up to 650-1.200°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 gauge10-30°C (50 - 86°F)
Gauge dimensions (HxWxL), from 2.000 x 1.700 x 600 mm (79 x 67 x 24”)
Electrical power requirements 230 VAC, 50Hz, 16A or 120VAC, (60 Hz)