The IMS-CCS flatness gauge creates a revolution in strip dimension measurement

April 7, 2015 - The IMS-CCS Flatness Gauge offers a degree of accuracy not found in other flatness measuring systems. As customers require increasingly tight tolerances, this gauge can help to maximize the acceptance rate of strip, sheet and plate processed on galvanizing, pickling, cutting-to-length, slitting and tension leveling lines in service centers and cold mills.

The Gauge is an optical measuring system that uses innovative camera cluster technology.  

It contains 50 cameras per 1000mm (39.4 in.) of inspection length and a laser line unit. The source head projects multiple laser lines across a strip’s width, and the lines are imaged using matrix cameras. These intelligent camera clusters provide superior data image processing. The topographical and flatness data they yield may be displayed on an HMI device for superior monitoring and control.

Note that CCS technology is the same technology used with the IMS-CCS width/hole/edge crack measuring systems and has a width accuracy of 0.1mm. 

The components are modular and can be extended to any required strip width.  Flatness calculations are made using proprietary software. 

The technology used is a variant of the patented IMS LasCon (laser contour) measurement systems. A change in height (ΔZ) used by vertical movements of the strip determines a shift (ΔY) in camera image.

The calculated height information related to strip width and height produces topographical information related to product surface. The quantitative evaluation of flatness occurs by dividing the strip, graphically, into multiple longitudinal adjoining fibers across the strip width. The strip is considered “flat” when all fibers have the same length. Different fiber elongation is caused by different downstream process steps which create “unflatness” calculated in I-units (difference of fiber length in 10µm of material). The IMS-CCS flatness system can measure wavelengths, especially at the edge locations, of less than 50mm.

The high density of fibers computed by the gauge, along with high sampling rates, make it possible to detect the smallest buckles and waves, especially on or near the strip’s edges. 

As for accuracy, the IMS-CCS Gauge can measure height direction of < 0.1mm (2σ) and has a permitted passline deviation of 100mm, with higher values possible. The gauge also has a measurement frequency up to 1kHz based on material surface and a measuring zone of 200 fibers/meter.

The gauge’s key advantages include accuracy to within 2σ on high-speed processing lines; precise reads of matte and glossy finishes independent of strip vibration on coating and cut-to-length lines, as well as on other processing lines;  reduced process disruptions, equipment damage and scrap; and easy installation. 

Key features include real-time data image processing that detects the smallest buckles and waves, especially on or near material’s edge, helping engineers and operators make informed decisions about strip flatness quality; high-resolution images of strip cross-direction to determine if strip meets specifications or needs re-work; system electronics located in control box which may be placed  in the vicinity of measuring equipment; compact and lightweight for easy integration  with production line where space is limited; and compatible with quality data management systems such as MEVInet-Q.

The MEVInet-Q data management system takes automated, real-time strip measurements by tracking and monitoring strip at every stage of production. 

The system stores those measurements for future use, including production previews. Through MEVInet-Q, production equipment is optimized through real-time statistical evaluations that can be displayed in web browsers, allowing for remote adjustments to production parameters and remote maintenance. Using MEVInet-Q results in improved product quality and lower production costs. 

As customers increasingly demand tighter tolerances, the use of highly precise measuring systems becomes necessary. Processors that fail to meet customers’ specifications most efficiently face higher costs of doing business due to re-work, rejects and lost accounts. The best gauges combine extreme precision with high affordability, and processors committed to growing their businesses prudently should take advantage of that powerful combination. MM

John Buckman is IMS’s General Manager and Vice president of Operations. For more information, contact Scott Dittrich, Sales Engineer, at Scott.Dittrich@ims-gmbh.de or visit www.imssystemsinc.com.