Metals Newsletter October 2015
Perfect Color Coating:
SURFACE MASTER can now see everything – every orange peel, every wrinkle
Finally, flawless Aluminum cold rolling – now made possible by
ISRA inline inspection
Save kilometers of material:
Now get the highest inspection performance in minutes thanks to
SURFACE MASTER can now see everything –
every orange peel, every wrinkle
Color coating on metal surfaces is a highly complex process: The material runs through a range of stations, and each one has an impact on the surface quality. Especially in end markets such as the construction, electrical or furniture industries, however, customers place the highest demands on product quality. The end product must be absolutely defect-free and show a consistent surface quality. As such, reliable optical surface inspection is a critical component in manufacturing high-quality color-coated strips.
The SURFACE MASTER inspection technology for color coating processes combines both quality inspection and process optimization in one. The particular performance capability of the inspection technology is the result of the sum total of highly intelligent, precise sensor technology, reliable 100% defect detection and accurate classification. All of this combined with intelligent software tools for running analyses and reports support the operator in gaining knowledge and expertise that he can use in the quality decision-making process. ISRA's technology is already known as a market leader in all of the aforementioned points. However, combining them into a single system creates maximum benefits. The result is an all-around carefree inspection package for the color coating process with a high degree of application competency in the metals industry based on countless successful installations around the world.
The patented DUAL SENSORTM technology combines line and matrix cameras providing surface inspection with BOTH direct and diffused light, thus making it possible to perfectly detect the full range of color coating defects such as low contrast spots and small dents and blisters. Crystal clear images of the surface can be created in the shortest exposure time. The defect detection is extremely reliable as well. Correct quality decisions can be made using only relevant data, based on existing outstanding defect classification. This way, users improve yield by minimizing scrap and increasing throughput.
During the surface inspection of the coating process, edge cracks can be detected and the width can be accurately measured thanks to inline technology. This allows manufacturers to produce a continuously uniform material quality, without having to install any additional sensor systems.
Flexible and precise reporting and analysis tools ensure systematic profit maximization for color coating lines. Critical coating parameters are observed and analyzed in order to improve the production processes. With the support of the defect trend analysis integrated in the system, flaw trends can be detected at an early stage and relevant counter measures can be introduced to prevent any further reduction in the quality of the product, avoiding any financial losses. Users can add production-specific software modules to the inspection technology, which can be applied toward intelligent decision-making. This reduces scrap in production significantly.
Conclusion: The inspection solution is the ideal basis to continuously improve and optimize production quality during the color coating process. Their use leads to maximum productivity, and coupled with the ease of integration and the fast start-up, users benefit from the shortest return on investment.
Finally, flawless Aluminum cold rolling –
now made possible by ISRA inline inspection
Restrictive and complex environmental conditions, such as very limited installation space, made inspection in the cold rolling mill virtually impossible. The global leader in metal inspection offers a solution in a new patented, integrated sensor. This smart solution provides reliable detection of "normal" and low-contrast, topographical defects such as roll marks, even without any additional supporting tools. This is particularly interesting and a pecuniary aspect for high quality requirements of aluminum cold rolling mills.
The new Multi-View sensor technology makes it possible to capture images of the same surface in several different illuminated views with only a single surface-scanning matrix camera. Even low-contrast defects can be reliably identified on highly reflective material at high production speeds of up to 2000 m/min. The technology can also clearly detect any kind of edge defect with the help of the flashed, ultra-bright LED illumination installed above and below the roller conveyor. Multi-step, hierarchically arranged classification tools assure that all surface defects are reliably categorized and classified. The fast classification technology, unmatched by anything else in the industry, is a critical component for the high detection and classification ratios. Complemented by advanced tuning tools, users also have the ability to optimize and to adapt the classification to suit their own needs in just a few easy steps.
The sensor does not require any additional support rolls or other stabilizing mechanism. The advantages are obvious when new damages on the strip surface are avoided and costs reduced as the system is integrated into the line. Particularly in the case of thin aluminum strip, the additional formation of roll structures or roll grooves on the material surface are prevented.
The sensors are so compact that they can be easily integrated into almost any installation space, no matter how small. The moveable push-in device - called MoveCab - also ensures easy maintenance.
SURFACE MASTER systems equipped with Multi-View sensors are unsusceptible to any kind of strip oscillation. The inspection systems can be supplemented with optional Expert5i software tools used for targeted optimization of the production process. Through the use of the systems, 100% secure decisions about the surface quality produced are made. They not only help to reliably provide the best surface quality, but also serve to optimize the manufacturing process and to maximize uptime.
Now get the highest inspection performance in minutes thanks to automatic optimization
The latest surface inspection systems often require a great deal of time to initially install and as a result can be extremely costly. Typically, before actually classifying the defects, they must first be categorized and the parameters must be defined. Manual parameter tuning can oftentimes take weeks or months to complete, and even the best results are not optimal. In contrast, the new automatic system tuning requires only a few short minutes to enable a "best-in-class" defect search with only a minimum number of defects.
Parameter tuning by hand is very time consuming and with the best result, fail to accomplish 100% reliable defect detection with the least possible "false positive", or pseudo defect, results. The new, fast tuning technology of SURFACE MASTER inspection systems enables easy defect categorization and an exceptionally fast automatic parameter optimization.
The automatic system-tuning is based on the experience of thousands of installations that have already been carried out at customer sites around the world. The fast tuning technology is equipped with a pre-installed set of defect classes, increasing the speed of implementation and initial installation considerably. Once the relevant defects have been marked, the system is able to find all comparable defects on its own, the user needs only to confirm.
Usually, at this point categories are broken down into four classes: critical defects and those of less significance, false positives and material structures. The "classifier" created in this manner now calculates various optimal solutions and offers a selection of first-class classifier set-ups. Because no defect detection can offer one single perfect solution, but instead several good options, the optimization task is solved using the Pareto principle, applying this unique method. Fast Tuning is able to automatically account for the complex dependencies between each of the individual parameters, a major step forward compared to previously used methods.
Parameters are optimized automatically based on the four categories using approximately 50 attributes for each individual defect. Automated algorithms are far superior to the manual process, in particular when the purpose is to find the best possible operating point in a 50-dimensional space, allowing defects to be ideally assigned.
Fast tuning is the latest example of how the global market leader in surface inspection, continues to come up with even more sophisticated automated methods to achieve the best surface inspection results, faster than ever before. In addition, metal manufacturers benefit from the significantly simplified handling and the lightning-fast set-up times of the inspection systems, reducing the return-on-investment to a minimum of the power-on time.