WireProfiler - Measurements of dimensions of bars and wire rods

The LIMAB WireProfiler system measures the outer diameter and ovality of bars and wire rods. The system can be installed in cold or hot rolling applications. The WireProfiler integrates up to 6 laser micrometer sensors for an accurate measurement of the produced product. The WireProfiler 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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WireProfiler

Basic Specification

Product ShapeDimension (mm)Dimension (inch)Temperature
RoundUp to 150up to 60-1200°C / 32-2200°F
Larger dimensions on request

Operating Principle
The WireProfiler integrates up to 6 LIMAB laser micrometer sensors. The micrometer sensors are based on shadow technology and in the WireProfiler system these sensors are mounted on a base plate around the object to be measured. Due to the technology the measurement accuracy is unaffected by vibrations and other movements of the material.

Applications

  • Diameter and ovality measurements of hot or cold rolled bars and wire rods
  • Final inspection and NDT-area for quality assurance

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 bars and wire rods. This feature gives the possibility to rapidly detect rolling mill problems like eccentric or damaged rolls.

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

Maintenance position
The WireProfiler 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 WireProfiler 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 WireProfiler includes all hardware, LIMAB-made sensors and software needed for any mill installation. LIMAB provides commissioning, training and on-going product support and service.

High performance diameter and ovality measurements
Very accurate diameter and ovality measurements with up to 12 measurement points around the circumference of the product. The WireProfiler system measures with a very high speed and performance.

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

Improved safety
Eliminates manual inspection of hot products by operators

Rugged design
The WireProfiler 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 WireProfiler integrates the LIMAB laser micrometer. The laser micrometer 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.

Bar & Wire rodDimension (mm)Dimension (inch)Temperature
Up to 150up to 60-1.200°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)