U.S. patent application number 13/226107 was filed with the patent office on 2013-05-09 for apparatus for determining gauge profile for flat rolled material.
The applicant listed for this patent is Britt Adamczyk, Lindsey Brown, Nicholas D. Carlevaris-Bianco, Han Huynh, Steve Michel, Jason Miller, Haley Nghiem, Eric Twiest, Brandon Wright. Invention is credited to Britt Adamczyk, Lindsey Brown, Nicholas D. Carlevaris-Bianco, Cato Clemens, Han Huynh, Steve Michel, Jason Miller, Haley Nghiem, Eric Twiest, Amber Woods, Brandon Wright.
Application Number | 20130111996 13/226107 |
Document ID | / |
Family ID | 40341580 |
Filed Date | 2013-05-09 |
United States Patent
Application |
20130111996 |
Kind Code |
A1 |
Miller; Jason ; et
al. |
May 9, 2013 |
APPARATUS FOR DETERMINING GAUGE PROFILE FOR FLAT ROLLED
MATERIAL
Abstract
A gauge profile apparatus (100) includes a gauge profile system
(104) and a lap count system (106) for determining an average
three-dimensional profile over the length of a sheet coil (10). The
gauge profile system (104) includes a lap profile measuring device
(112) which will make a distance determination between top and
bottom surfaces for the sheet coil (10). The lap count system (106)
includes a distance sensor (288) and camera (290) for determining
the average thickness of the sheet coil (10). A second embodiment
of the gauge profile system (400) is also provided, which utilizes
a PDA (404), an ultrasonic tester (406) and a string encoder
(432).
Inventors: |
Miller; Jason; (Ada, MI)
; Carlevaris-Bianco; Nicholas D.; (Midland, MI) ;
Nghiem; Haley; (Holland, MI) ; Twiest; Eric;
(Grand Rapids, MI) ; Woods; Amber; (Holland,
MI) ; Wright; Brandon; (Belleville, MI) ;
Clemens; Cato; (Grand Haven, MI) ; Huynh; Han;
(Zeeland, MI) ; Michel; Steve; (US) ;
Brown; Lindsey; (Grand Rapids, MI) ; Adamczyk;
Britt; (Grandville, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Miller; Jason
Carlevaris-Bianco; Nicholas D.
Nghiem; Haley
Twiest; Eric
Wright; Brandon
Huynh; Han
Michel; Steve
Brown; Lindsey
Adamczyk; Britt |
Ada
Midland
Holland
Grand Rapids
Belleville
Zeeland
Grand Rapids
Grandville |
MI
MI
MI
MI
MI
MI
MI
MI |
US
US
US
US
US
US
US
US
US |
|
|
Family ID: |
40341580 |
Appl. No.: |
13/226107 |
Filed: |
September 6, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12672050 |
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PCT/US08/09364 |
Aug 4, 2008 |
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13226107 |
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60963221 |
Aug 3, 2007 |
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Current U.S.
Class: |
73/632 |
Current CPC
Class: |
G01N 2291/0234 20130101;
G01B 17/02 20130101; G01N 29/04 20130101; G01N 29/07 20130101; G01B
11/06 20130101 |
Class at
Publication: |
73/632 |
International
Class: |
G01N 29/04 20060101
G01N029/04 |
Claims
1. A gauge profile apparatus adapted for use with a sheet coil for
determining an average three-dimensional profile over the length of
the coil, said profile apparatus comprising: a gauge profile system
for determining the relative distribution of material of said sheet
coil for a cross-section of said material, said gauge profile
system having an ultrasonic gauge device for bombarding said
material of said sheet coil with high frequency waves; and a lap
count system comprising an ultrasonic distance sensor and camera,
for determining the average thickness of said sheet coil, through
counting of a number of laps of said sheet coil and making a
determination of an outside diameter of said sheet coil and an
inside diameter of said sheet coil.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority of
U.S. patent application Ser. No. 12/672,050 filed Feb. 3, 2010,
which is a United States National Stage application under 35 U.S.C.
.sctn.371 of International Patent Application Serial No.
PCT/US08/009364 filed Aug. 4, 2008, with the international
application claiming priority of U.S. Provisional Patent
Application Ser. No. 60/963,221 filed Aug. 3, 2007.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFISHE APPENDIX
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The invention relates to industrial measurement systems and,
more particularly, to apparatus and methods for determining gauge
profiles for rolled materials.
[0006] 2. Background Art
[0007] Throughout relatively recent history, a substantial amount
of development work has occurred with respect to apparatus and
processes for manufacturing, forming and shaping various types of
materials, including, for example, metallic materials. One such
metallic material in worldwide use is steel. Steel has been used
for a substantial part of relatively modern history. Steel is an
alloy consisting mostly of iron, with a carbon content often within
the range of 0.02% to 2.04% by weight, typically depending on
grade. Although carbon is the most cost-effective alloying material
for iron, various other elements may be used, such as manganese and
tungsten. The carbon and other elements act as a hardening agent,
preventing dislocations in the iron atom crystal lattice from
sliding past one another. The amount of alloying elements and the
form of their presence in the steel (e.g. solute element,
precipitated phase) controls qualities such as the hardness,
ductility and tensile strength of the resulting steel.
[0008] Long before even the Renaissance, steel was produced by
various and what may be characterized as "inefficient" methods.
However, steel use became more common after more efficient
production methods were devised in the 17th Century. With the
invention of the Bessemer process in the mid-19th century, steel
became what was then a relatively inexpensive mass-produced good.
Further refinements in the process (e.g. basic oxygen steel making)
lowered cost of production, while increasing metal quality. Today,
modern steel is generally identified by various grades of steel
defined by various standards organizations.
[0009] Today, steel and other materials are produced and generated
through various apparatus so as to obtain differing sizes and
shapes of the resultant products. For example, one known method for
forming and shaping steel utilizes a process known as "continuous
casting." This process involves the pouring of liquid steel
directly into semi-finished shapes, such as slabs, blooms, blanks,
or billets. The continuous casting process typically produces a
slab of steel having certain ranges of pigments and width. These
slabs are often cut into pieces of varying lengths, dependent upon
commercial particulars. In some instances, it is desired to produce
a flat, rolled steel strip from such material. To produce such a
rolled steel strip, a discreet slab can be reheated, and passed
through one or more hot rolling millstands. Such hot rolling
procedures can result in reducing the thickness to, for example,
approximately 2.5 millimeters. To obtain further reductions in
thicknesses, the materials resulting from the hot rolling process
can be passed through one or more reducing/finishing cold rolling
millstands.
[0010] Other advancements in technologies associated with the
rolling of metallic stock (such as stripped steel or the like) have
been made during the last several decades. These advances have
applied not only to steel, but to other types of metals. In fact, a
substantial amount of research and development has occurred during
the past several years with respect to the rolling of non-metallic
products, such as plastics and the like.
[0011] In the rolling of material stock, such as steel, a problem
has existed with respect to maintaining a uniform gauge or
thickness of the material during the rolling process.
Correspondingly, this problem has also been presented with respect
to means for measuring the gauge or thickness after the rolling
process has been completed. In this regard, it is particularly
difficult to obtain gauge measurements when the steel or other
materials are in a coiled configuration. For example, certain
organizations may operate as steel service centers, which purchase
coiled sheet steel from rolling mills. Such service centers may,
for example, function so as to slit or otherwise process the coiled
sheet material for customers, which may include stampers, roll
formers and the like. In the past, it has been substantially
difficult to obtain an accurate determination of coil thickness or,
what may be characterized as a "gauge profile," prior to
undertaking the slitting or other processes being performed by the
service center. However, the slitting of the coiled sheet material
cannot be undertaken until after there is a customer allocation for
the service center. Accordingly, the service center cannot obtain
an accurate gauge profile until after such customer allocation are
exposed to substantial monetary risks due to an inability to
accurately determine coil thickness prior to processing. These
risks are comprised of losses through devalued material, lost
machine time, lost freight, customer downtime and subsequent
effects.
[0012] Various systems have been developed and are known in the
prior art which are directed to material gauge measurements and
facilitating the accuracy thereof.
[0013] For example, Hold, U.S. Pat. No. 4,542,297 issued Sept. 17,
1985, discloses an apparatus for measuring a thickness profile of
steel strip. The apparatus includes a radiation source which is
reciprocally movable in a stepwise fashion across the strip width
on one side thereof. A single, elongated detector on the other side
of the strip is aligned with the scanning source. This detector may
be a fluorescent scintillator responsive to the incident radiation.
In turn, the incident radiation is dependent on the degree of
absorption by the strip.
[0014] In addition to the foregoing, Hold discloses apparatus for
sensing the degree of excitation in the detector, with the sensing
occurring in synchronism with the scanning source. This combination
is used to provide an output which is considered to be
representative of the thickness profile of the steel strip. The
profile is then displayed on a television screen. A thickness gauge
(disclosed as being "conventional" by Hold), which may involve
x-ray technology, is used in conjunction with the profile gauge, so
as to compensate the output of the profile gauge for any variations
in the strip thickness along the length of the coil.
[0015] Hold further describes the concept that the current market
for hot rolled strip (with the term "strip" being described by Hold
as including "sheet" and "plate" steel) requires a relatively
smooth and cigar-shaped profile. Hold states that desired profiles
have less than 5 microns edge-to-edge thickness differential. In
addition, Hold also states that the "crown" should be less than 70
microns. The crown is defined as being the difference between the
thickness at the edges of the strip and the center thickness of the
strip. It should be noted that Hold is describing thickness
measurements occurring as the strip is being rolled.
[0016] Hold further describes the concept that the measurement
information has previously been obtained off-line from contact
measurements. However, such off-line measurements only provide what
are considered to be "historical" measurements. Prior systems have
been used which can be characterized as being "on-line" through the
use of a scanning mechanism providing a relatively rapid read-out.
In this manner, Hold describes the concept that relatively rapid
corrective action may be taken. With the on-line system,
measurements are taken across the width by combining the physical
traverse of a single radiation source and an associated detector on
two limbs of what is characterized as a "C"-frame across the strip.
Alternatively, a physical traverse of a single radiation source may
be made across the strip with a series of fixed detectors on the
other limb, or a series of fixed sources with equal or different
fixed detectors. Hold states that movement of the frame is
relatively cumbersome, slow and energy consuming. Alternative
movements of individual source/detector apparatus in synchronism is
characterized by Hold as being relatively complex. Also, with two
moving mechanisms, wear and inertia are considered problems. In an
embodiment using a series of fixed detectors, measurements can be
made only at a number of discrete points, and difficulties may
arise in "collection" of the data from these detectors, as well as
ensuring that each detector responds to radiation incident only on
itself and not on adjacent detectors.
[0017] In Hold, the radiation source is a radio-isotope (which may
be Americium 241) which is driven across the strip width and
relatively rapid discrete steps by a pulsed "stepper" motor.
Further, a linear array of such sources is disclosed, disposed in
the direction of the travel of the strip for purposes of enhancing
the output.
[0018] The detector is considered to be continuous in the sense
that it is a single integrated unit. As earlier described, the unit
may be a fluorescent plastic scintillator, with a massive number of
scintillation particles being embedded in a plastic matrix. Light
output from these particles is collected by photomultipliers
mounted on each end of the plastic rod. The edge of the strip,
utilized as the datum for the trace, is identified by an
instantaneous change in the amount of radiation incident on the
scintillator, as the source transverses the strip edge. The
time-base for the trace (i.e. the x-coordinate) is considered to be
governed by the stepper motor at each step, so as to effect the
reciprocating scan across the strip.
[0019] In brief summary, Hold discloses an apparatus for measuring
profile thickness which utilizes a radiation source and detector in
order to determine the strip profile. This apparatus essentially
does a "head-to-tail" representation, by performing linear gamma
inspection across the face of the strip at multiple points. It
should be noted that Hold requires that the steel strip not be in
an coil form. Instead, if the strip had been coiled, the coil needs
to be opened up and traverse the measuring apparatus, in order to
gather the requisite information.
[0020] A relatively earlier apparatus for measuring thickness of
sheet metal and the like is disclosed in Bendix, et al., U.S. Pat.
No. 2,935,680 issued May 3, 1960. The Bendix device is specifically
directed to gauging the thickness of sheets of magnetizable metal.
The apparatus includes two equivalent electromagnets, each having a
central core and a surrounding pole. A coil is supported on each
core, with a common alternating current source for the coils. The
source is sufficient so as to cause the sheets under test to be
magnetically saturated by the electromagnets during at least a
portion of the alternating current cycle. The core and the pole of
the first magnet are bridged by a reference sheet of metal, and the
core and pole of the second magnet are bridged by the sheet of
metal under test. Branch resistance circuits are connected to the
alternating source on opposite sides of the coils, and an
adjustable resistance unit is connected to the resistance circuits.
The adjustable resistance unit is connected to the alternating
current source intermediate the coils, and a means for indicating
measurements is positioned in series with the adjustable unit.
[0021] In summary, the apparatus disclosed in Bendix, et al. uses
an alternating current, and a process which induces and measures
the magnetic field around a charged sheet as the sheet flows into a
die. The apparatus essentially measures the timing required for the
entering material to become magnetically saturated. The timing is
then translated into a thickness measurement. Again, Bendix, et al.
requires any material under test to be unrolled and to enter the
measurement system one layer or one sheet at a time. Also, it is
obvious that in view of their required magnetic characteristics,
the Bendix, et al. system is limited to measurement of ferrous
materials.
[0022] Bertin, et al., U.S. Pat. No. 4,301,366 issued Nov. 17, 1981
discloses an apparatus and processes for measuring strip
thicknesses in a material strip generated as an output from a mill.
A radiation source and detector are positioned at a gauging
station, with the stream of material moving pass the station. As
the material moves pass the station, an electrical signal is
generated which varies as a function of the material at the
station. The signal includes a lower frequency component, higher
frequency cyclical component and higher frequency noise component.
A circuit for providing a thickness output varying as a function of
the lower frequency component of the signal, and a circuit
providing an output indicating chatter varying as a function of the
higher frequency cyclical component, are utilized. Bertin, et al.
also disclose apparatus for providing both digital and analog
versions of their system.
[0023] In general, Bertin, et al. disclose an apparatus and methods
for detecting "chatter" in systems directed to thickness measuring
of strip products. More specifically, in processes such as the cold
rolling of steel, there may be relatively prolonged regions of high
frequency variations in the product. An example is a thickness
variation, which is commonly referred to as chatter. A relatively
common cause of chatter is a mechanical resonance in the rolling
mill, which tends to make the rolls "bounce." This activity gives
rise to a thick (or thin) spot in the steel strip for each bounce.
These thickness variations can be considered to be quality defects.
More specifically, a primary purpose of the Bertin, et al. system
is to collect thickness information so as to detect signs of
chatter. The chatter can be characterized as a symptom of the
harmonic bouncing of the gauge-reducing rollers which show up in
the material as cyclical thickness variations across the length of
the material strip. As with certain of the aforedescribed
references, the Bertin, et al. apparatus cannot be utilized with
material strips, while the strips are in coil form. Also, it
appears that Bertin, et al. require that the material strip be in
motion relative to the gauging or chatter measuring station.
[0024] Another relatively early disclosure of an apparatus and
method for determining average thicknesses of metallic strip
materials from rolling mills is set forth in Deul, Jr., et al.,
U.S. Pat. No. 2,356,660 issued Aug. 22, 1944. The patent describes
the concept that in the rolling of metallic stock, such as strip
steel, it is a problem to measure the thickness of the material
during the rolling process, and to obtain some means of determining
the thickness throughout the entire width of the traveling strip
material. The disclosed measuring apparatus is used while the strip
material is being coiled on a reel. A radial reel zone is provided,
with a counting apparatus for determining the number of revolutions
of the reel corresponding with the predetermined radial thickness
of the coil strip defined by the entry and exit of the outer face
of the coiled strip on the reel. A synchronistic control is
utilized with the counting apparatus which includes an actuating
member driven in synchronistic relationship with the reel.
Mechanical clutching devices are utilized intermediate the
rotatable coil winding reel and the revolution counter, and control
apparatus are utilized for synchronizing the starting and stopping
of the counting mechanism. The automated control apparatus includes
photo-electric control devices, with a series of light beams being
generated coincident with the strip surface at the beginning of the
radial zone. A second beam is disposed so as to be coincident with
the strip surface at the ending of the radial zone. In general, the
Deul, Jr. et al. patent reference discloses a method for
calculating the average thickness of coiled materials by measuring
the elevation of the coil from the mandrel that the materials are
being spooled onto, and dividing this measurement by the number of
laps. As with other known systems, the Deul, Jr., et al. system is
not utilized with the material while it is in coil form, but
instead it counts the number of turns a device makes in the coiling
process, thus requiring motion. Also, this system essentially
"assumes" that the cross section of the coil material is a true
rectangle. That is, the system does not take into account the
commonly known edge-crown-edge profile which results during
manufacture of various types of rolled material strips.
[0025] As previously described herein, a number of the known, prior
art systems for measuring material strip thicknesses must be
utilized while the strip is in an "unrolled" or "uncoiled" state.
However, as also previously described, for companies such as steel
service centers which purchase sheet steel in coiled states, it has
been extremely difficult to determine strip gauge. To date, certain
processes for estimating gauge ranges are known for use with coils
consisting of sheet steel or the like. Some of the known gauge
range estimates are created from measurements which consist of the
highest and lowest micrometer/caliper readings which are typically
taken during a receiving process for the coils on the production
floor. Unfortunately, the only portions of the incoming coil which
are accessible for purposes of taking these readings essentially
comprise the edges and the outside/inside laps of the coil. These
areas are inherently considered to be the most erratic and least
"representative" areas of the coil. For example, edges of coils
typically have a "feather" affect and provide relatively low
thickness measurements. Correspondingly, heads and tails of coils
are typically high and provide relatively large thickness
measurements. These circumstances result in the generation of
unreliable data. It is apparent that such unreliable data can
result in attempts to apply coils improperly to customer
orders.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0026] The invention will now be described with reference to the
drawings, in which:
[0027] FIG. 1 is a perspective view of a sheet steel coil which may
be utilized as a work piece under test with a gauge profile
apparatus in accordance with the invention;
[0028] FIG. 2 is an illustration showing a cross section of a coil
and the relationship between thicknesses of coil edges and the coil
crown;
[0029] FIG. 3 is a partially diagrammatic and partially block
diagram indicating the processes associated with the gauge profile
apparatus in accordance with the invention, and the specific input
and output parameters utilized by the apparatus in accordance with
the invention;
[0030] FIG. 4 is a diagrammatic view of a cross section of a coil
under test, and the physical positioning of a gauge profile system
utilized with the apparatus in accordance with the invention;
[0031] FIG. 5 is a diagrammatic illustration of the relative
positioning of the coil under test with a lap count system which
may be utilized with the apparatus in accordance with the
invention;
[0032] FIG. 6 is a perspective view of a linear slide which may be
utilized with the gauge profile system;
[0033] FIG. 7 is a graphic illustration of the relationship among
power, speed and torque characteristics of a stepper motor which
may be utilized with the gauge profile system in accordance with
the invention;
[0034] FIG. 8 illustrates a bearing compartment which maybe
utilized as part of an ultrasonic thickness sensor for the gauge
profile system in accordance with the invention;
[0035] FIG. 9 is a perspective view of a plug bearing which may be
utilized with the bearing compartment illustrated in FIG. 8;
[0036] FIG. 10 is a vertical cross section of the bearing plug
illustrated in FIG. 9;
[0037] FIG. 11 is a perspective view of a platform and clamping
configuration for the sensor utilized with the gauge profile system
in accordance with the invention;
[0038] FIG. 12 is a partially elevation and partially diagrammatic
view of certain components of the sensor platform and clamping
configuration illustrated in FIG. 11;
[0039] FIG. 13 is a perspective view of the interior of the driven
sprocket enclosure and associated components which may be utilized
with the gauge profile system in accordance with the invention;
[0040] FIG. 14 is a further perspective view of the driven sprocket
enclosure illustrated in FIG. 13, but showing the enclosure in a
state with the cover secured thereon;
[0041] FIG. 15 is a block diagram of certain components associated
with the control system for the gauge profile system in accordance
with the invention;
[0042] FIG. 16 is a partially perspective view of a stand which may
be utilized with a lap count system which, in turn, may be utilized
with the gauge profile apparatus in accordance with the
invention;
[0043] FIG. 17 is a partially perspective and exploded view of the
stand illustrated in FIG. 16;
[0044] FIG. 18 is a partially diagrammatic and partially functional
block diagram of the control system for the lap count system in
accordance with the invention;
[0045] FIG. 19 is an image in an original state which was produced
from a prototype of the lap count system in accordance with the
invention;
[0046] FIG. 20 is an illustration of a partial image acquisition
utilizing processes performed by the lap count system in accordance
with the invention;
[0047] FIG. 21, like FIG. 19, illustrates an original image of the
coil laps as produced by the lap count system in accordance with
the invention;
[0048] FIG. 22 is an image of the laps illustrated in FIG. 21
following an image averaging procedure undertaken by the lap count
system in accordance with the invention;
[0049] FIG. 23 illustrates a plot of grayscale values obtained by
the lap count system in accordance with the invention, along the
coil radius;
[0050] FIG. 24 is an illustration of the frequency characteristics
of a low pass filter which may be utilized with the lap count
system, for purposes of noise reduction;
[0051] FIG. 25 is an illustration of averaged grayscale values
similar to FIG. 23, but with the plot utilizing data filtered
through the low pass filter with the characteristics illustrated in
FIG. 24;
[0052] FIG. 26 is a photographic image showing a raw photograph of
the coil laps taken through the use of the lap count system in
accordance with the invention;
[0053] FIG. 27 is a plot of the average grayscale values along the
coil radius generated through the use of a lap count system;
[0054] FIG. 28 is similar to FIG. 27, but illustrates the plot of
grayscale values after focusing techniques have been applied to the
lap count system in accordance with the invention;
[0055] FIG. 29 is a perspective view of a second embodiment of a
gauge profile system which may be utilized in accordance with the
invention;
[0056] FIG. 30 is an exploded view of the gauge profile system
illustrated in FIG. 29;
[0057] FIG. 31 is a perspective view of the case assembly of the
gauge profile system illustrated in FIG. 29;
[0058] FIG. 32 is a perspective view of the case bottom of the case
assembly shown in FIG. 31;
[0059] FIG. 33 is a perspective view of the case bottom plate of
the case assembly shown in FIG. 31;
[0060] FIG. 34 is a perspective view of the case top plate of the
case assembly shown in FIG. 31;
[0061] FIG. 35 is a partially perspective view of the roundabout of
the case assembly shown in FIG. 29;
[0062] FIG. 36 is a perspective view of a PDA standoff of the case
assembly shown in FIG. 29;
[0063] FIG. 37 is a perspective view of an Olympus standoff of the
case assembly shown in FIG. 29;
[0064] FIG. 38 is a perspective view of the battery bottom clamp of
the case assembly shown in FIG. 29;
[0065] FIG. 39 is a perspective view of a battery top clamp of the
case assembly shown in FIG. 29;
[0066] FIG. 40 is a perspective view of the wand assembly of the
case assembly shown in FIG. 29;
[0067] FIG. 41 is a perspective view of the wand handle of the wand
assembly shown in FIG. 40;
[0068] FIG. 42 is a perspective view of the wand bottom plate of
the wand assembly shown in FIG. 40;
[0069] FIG. 43 is a perspective view of the wand main of the wand
assembly shown in FIG. 40;
[0070] FIG. 44 is a perspective view of the wand cover of the wand
assembly shown in FIG. 40;
[0071] FIG. 45 is a partially schematic and partially diagrammatic
illustration of the gauge profile system as utilized with the lap
count system;
[0072] FIG. 46 is a simplified perspective view of the gauge
profile system as it may be utilized with the sheet coil;
[0073] FIG. 47 shows a pair of images of the PDA of the gauge
profile system, illustrating a simulated image file and data that
will be saved;
[0074] FIG. 48 is an illustration of the encoder signal structure
which may be utilized with the string encoder of the gauge profile
system;
[0075] FIG. 49 is a perspective view of the transducer wand
utilized with the gauge profile system;
[0076] FIG. 50 is an exploded view of the wand assembly for the
gauge profile system, showing various components of the wand
assembly as previously illustrated in individual illustrations;
[0077] FIG. 51 is a block diagram illustrating a functional
sequence for the serial relay controller;
[0078] FIG. 52 is a block diagram showing functional steps
associated with the encoder count controller;
[0079] FIG. 53 is a functional state diagram of the software
utilized with the PDA for the gauge profile system;
[0080] FIG. 54 is a state functional block diagram illustrating the
"start" state;
[0081] FIG. 55 is a state functional block diagram illustrating the
"add coil" state;
[0082] FIG. 56 is a state functional block diagram showing the
"import coils data file" state;
[0083] FIG. 57 is a state functional block diagram illustrating the
"gauge testing" state;
[0084] FIG. 58 is a state functional block diagram showing the
"data transfer" state;
[0085] FIG. 59 is a state functional block diagram showing the
"process the collected data" state; and
[0086] FIG. 60 is an illustration of an example set of equations
which may be utilized with "curve-best-fit" equations for the data
collected.
DETAILED DESCRIPTION OF THE INVENTION
[0087] The principles of the invention will now be described with
respect to a gauge profile apparatus 100 disclosed herein and
primarily illustrated in FIGS. 3-28. The gauge profile apparatus
100 includes a gauge profile or cross-section profile system 104,
and a lap count system 106. In addition to the gauge profile system
104, a second embodiment of a gauge profile system is also
disclosed herein. The second embodiment is described herein as
gauge profile system 400 and is illustrated in FIGS. 29-60. It
should be emphasized that whether the lap count system 106 is used
with the gauge profile system 104 or the gauge profile system 400,
the resultant purposes for a gauge profile apparatus in accordance
with the invention are the same. The gauge profile apparatus 100 is
adapted to be used with flat rolled materials which have been
formed into coils. The materials may be sheet steel, other types of
metals or other types of materials (such as plastics or the like).
The primary purpose of the gauge profile apparatus 100 is to
project or otherwise "estimate" the gauge thickness at any point of
a coil with a relatively high degree of accuracy. The resultant
output from the gauge profile apparatus 100 can be characterized as
a three dimensional ("3D") gauge projection.
[0088] As previously described in the section entitled "Background
Art," companies such as steel service centers purchased coiled
sheet steel from various mills. Service centers, such as the
assignee of the current invention, may undertake activities such as
slitting the coiled sheet steel for use by various stampers and
roll formers. As also earlier described, material can be
compromised as a result of an inability to accurately determine
coil thickness prior to slitting. Also, problems exist with respect
to lost machine time, lost freight, customer downtime and the like.
For purposes of describing concepts associated with determination
of coil thicknesses, an example embodiment of a sheet coil 10 is
illustrated in FIG. 1. A cross section of the sheet coil 10 is
further illustrated in FIG. 2. As shown therein, the sheet coil 10
may consist of sheet steel or other materials, as previously
described. Parameters associated with the sheet coil 10 are
illustrated in FIG. 1, and include a series of laps 18. The
outermost lap is shown as the outside lap 12 while the innermost
lap is shown as inside lap 14. The difference in relative positions
of the ends of the outside lap 12 and inside lap 14 is shown as the
overlap length 16. The outermost diameter of the coil 10 is
identified as the outside diameter 20, while FIG. 1 also
illustrates the inside diameter 22. A lap count radius 24 is
further shown in FIG. 1, and is defined as the radial length
between the center point of the sheet coil 10 and the outside lap
edge 12. In turn, the total coil thickness 26 is defined as the
thickness of the total number of laps, as illustrated in FIG.
1.
[0089] Currently, gauge range estimates, when not provided by
outside processors of the coiled sheet materials, are typically
created from highest and lowest micrometer/caliper readings taken
during the receiving process on the production floor.
Unfortunately, however, and as apparent from the overall shape and
configuration of the sheet coil 10 shown in FIG. 1, the only
portions of the sheet coil 10 that are accessible for purposes of
taking such readings are the edges, outside lap 12 and inside lap
14. However, these areas of the sheet coil 10 are known to be
inherently the most erratic and least representative areas of the
sheet coil 10. More specifically, the edges typically have what can
be considered a "feather" effect and are relatively low. In
contrast, the "heads" and "tails" of the sheet coil 10 are
typically high. Such circumstances generate unreliable data which
often results in an attempt to apply sheet coils improperly to
customer orders.
[0090] In this regard, it has been noted that rolls generated at
steel mills and the like typically have a slightly concave shape
for purposes of controlling the direction of slabs/coils, while
performing gauge reduction. The result of the shape is a coil which
would typically have the cross section of sheet coil 10 illustrated
in FIG. 2. It should be emphasized that FIG. 2 is somewhat of an
"exaggerated" cross section for purposes of description. As shown
therein, the relative center of the sheet coil 10 has a thickness
which is greater than the thickness which exists at its edges. For
purposes of description, FIG. 2 illustrates the sheet coil 10 as
having an edge gauge 28. The thickness portion 30 of the sheet coil
10 is at or near the center of the coil 10, and is typically
referred to as the crown or crown gauge 30. The actual amount of
crown will typically vary from mill to mill and, in fact, even coil
to coil.
[0091] Notwithstanding the foregoing, it has been found that
although the gauge of the sheet coil 10 can change from head to
tail, the relative thickness between the edge gauges 28 and the
crown gauge 30 will remain relatively constant. Accordingly, if the
width, weight and length of the sheet coil 10 could be accurately
determined, and a relatively accurate profile of the crown 30 could
be ascertained, then the gauge at any point of the sheet coil 10
should possibly be able to be projected with a relatively high
degree of accuracy.
[0092] FIG. 3 illustrates a partially symbolic and partially
functional block diagram of the inputs, outputs and processes
performed by the gauge profile apparatus 100. As previously stated,
the ultimate output desired through the use of the gauge profile
apparatus 100 in accordance with the invention is an average
three-dimensional profile over the length of the sheet coil 10.
Referring specifically to FIG. 3, the gauge profile apparatus 100
is shown as having a symbolic boundary 102. The apparatus 100
essentially comprises two main or primary systems; namely, a gauge
profile or cross-section profile system 104 and a lap count system
106. The symbolic boundaries of the systems 104, 106 are
illustrated in FIG. 3.
[0093] The gauge profile or cross section profile system 104
essentially determines the relative distribution of material of the
sheet coil 10 for a cross section of the material. As will be
described in subsequent paragraphs herein, and in accordance with
one embodiment of the invention, the gauge profile system 400
utilizes an ultrasonic gauge device for bombarding the sheet coil
material with high frequency sound waves. Accordingly, inputs for
the gauge profile system 104 are symbolically illustrated in FIG. 3
as being the sheet coil 10 shown as input 108 and a determined coil
sound velocity 110. The inputs 108, 110 are applied to a lap
profile measuring device 112, which effectively measures the
outside/inside lap profile. The lap profile measuring device 112
will essentially take the results of the bombardment of the sheet
coil 10 with the high frequency sound waves, and translate the
timing between the wave reflections or "echoes," into a distance
determination between top and bottom surfaces for the sheet coil
10. As will be described in subsequent paragraphs herein, the lap
profile measuring device 112 or calculations associated therewith
are used in conjunction with a linear slide system which allows for
the ultrasonic gauge measurement to traverse across the width
(shown as width 34 in FIG. 1) of the sheet coil 10, while
simultaneously capturing thickness measurements during traverse.
The output of the lap profile measuring device 112 is therefore
shown symbolically in FIG. 3 as the lap profile parameter 114.
[0094] As earlier stated, the gauge profile apparatus 100 also
includes, in addition to the gauge profile system 104, a lap count
system 106. The system 106, and the particular embodiment of the
gauge profile apparatus 100 in accordance with the invention,
comprises a system using a commercially available ultrasonic
distance sensor and camera (with the camera having an internal
processor) for purposes of determining the average thickness of the
sheet coil 10. This determination is achieved through the counting
of the exact number of laps of the sheet coil 10, as well as making
a determination of the outside diameter of the sheet coil 10 and
the inside diameter of the sheet coil 10. As will be made apparent
from subsequent description herein, this information, combined with
a measurement of the width 34 of the sheet coil 10, allows for the
volume of the sheet coil 10 to be determined with a substantial
amount of relative accuracy. With the volume combined with a weight
measurement, a determination of the "average gauge" of the sheet
coil 10 may be determined.
[0095] More specifically, and turning to FIG. 3, the illustration
shows, somewhat symbolically and somewhat diagrammatically, an
input to the lap count system 106 as comprising the coil weight
116. The coil weight 116 can be determined by any suitable and well
known apparatus and procedures. In addition to the coil weight 116,
the material density 118 and the width (shown symbolically in FIG.
3 as width 120) are applied as input parameters to a functional
calculation which can be characterized as an average lap gauge
calculator 124. The output of the average lap gauge calculator 124
is a representation of the average lap gauge, shown as lap gauge
126 on an output from the average lap gauge calculator 124.
[0096] In addition to the inputs consisting of the coil weight 116,
material density 118 and width 120, the lap count system 106 also
includes, as an input, the overall shape and configuration of the
sheet coil 10. Through the use of the aforedescribed distance
sensor and camera, coil dimensions can be obtained, through the
devices shown in a symbolic format as the coil dimension calculator
128. Again, the calculator 128 is merely a symbolic representation
and clearly includes input parameters coming from outputs of a
distance sensor and camera.
[0097] The outputs of the coil dimension calculator 128 are
illustrated as outputs 130, 132, 134 and 138. More specifically,
output 130 represents a determination of the outside diameter
(previously shown in FIG. 1 as outside diameter 20 of the sheet
coil 10). The output 132 consist of the inside diameter (previously
identified as the inside diameter 22 in FIG. 1). Correspondingly,
output 134 represents the lap count (identified as the number of
laps 18 in FIG. 1). These output parameters can be determined with
relatively high accuracy. Each of these outputs consisting of the
outside diameter, inside diameter and lap count are applied as
inputs to devices which can calculate the length of the sheet
material of the sheet coil 10. This coil length determination is
symbolically shown in FIG. 3 as being made by the coil length
calculator 136. The output of the coil length calculator 136 is the
output shown in FIG. 3 as coil length parameter 140. The coil
length parameter 140, in turn, is applied as an input to the
previously described average lap gauge calculator 124. With the
information consisting of the coil weight 116, material density
118, width 120 and coil length 140, the average lap gauge
calculator 124 can readily determine the average lap gauge 126.
[0098] As further shown in FIG. 3, the gauge profile apparatus 100
applies the output of the lap gauge calculator 124, consisting of
the average lap gauge 126, as an input to what is referred to in
FIG. 3 as an average 3D profile calculator 142. Also applied as an
input to the profile calculator 142 is the previously described lap
profile 114 which comprises the output from the gauge profile
system 104. With the lap profile 114 and average lap gauge 126, the
3D profile calculator 142 can generate an estimation of the average
3D profile over the entirety of the length of the sheet coil 10.
This is shown as average 3D gauge profile parameter 144. In
addition to the output 144 consisting of the average 3D gauge
profile, the gauge profile apparatus 100 can also be utilized to
generate a parameter shown in FIG. 3 as the peak-to-peak distance
138. These distances can be calculated directly by the coil
dimension calculator 128 through the measurement of the parameters
of the sheet coil 10.
[0099] Physical element description, as well as additional
functional description, will now be provided for the gauge profile
system 104, primarily with respect to FIGS. 4 and 7-15. FIG. 4
illustrates relative positioning of the physical configuration of
the gauge profile system 104 on the sheet coil 10, with the sheet
coil 10 shown in partial cross section in FIG. 4. With reference
thereto, the gauge profile system 104 includes a linear slide, the
major components of which are also illustrated in FIG. 6. The
linear slide 150 includes an end block 152 having a reversal block
153 (see FIG. 6) mounted therein. The linear slide 150 also
includes an upper belt arm 154 and a lower belt and slide arm 156,
the arms 154 and 156 being spaced apart and parallel to each other.
For purposes of securing the gauge profile system 104 to the sheet
coil 10 during measurement procedures, the linear slide 150 also
includes an end clamp 158 which clamps the linear slide to one end
of the sheet coil 10. A second clamp identified as adjacent clamp
160, is utilized to clamp the linear slide 150 to the other edge of
the sheet coil 10. In addition to the foregoing, and consisting of
one of the principal elements of the gauge profile system 104, a
thickness sensor 162 is included which is moveably mounted to the
lower belt and slide arm 156. As described earlier herein, the
thickness sensor 162 is a commercially available ultrasonic gauge
device which will bombard the sheet coil 10 with high frequency
sound waves. The timing between wave reflections or echoes can be
translated into distance determinations between top and bottom
surfaces for the sheet coil 10. The purpose for the linear slide
150 is to provide a means for permitting traverse of the thickness
center 162 across the width of the sheet coil 10, while capturing
thickness measurements during traversal.
[0100] Mounted to the end of the linear slide 150 is a control box
164, which contains both mechanical and electronic elements for the
gauge profile system 104. More specifically, the control box 164
can be mounted to the adjacent clamp 160. Power for the control box
164 can be provided as AC power 166 through a power cord 168.
Further, if desired, signals can be transmitted between a desktop
computer or the like (not shown) and the control box 164 through
antenna 170. These signals are illustrated as spatial signals 172
in FIG. 4. It should be noted that FIG. 6 illustrates the linear
slide 150 in the absence of the thickness sensor 162.
[0101] More specifically with respect to FIG. 6, the control box
164 is illustrated with the absence of a control box cover 174,
which is illustrated in FIG. 14. As shown primarily with respect to
FIGS. 6 and 13, the gauge profile system 104 includes a driver belt
system 176, the major components of which are located within the
control box 164. As shown primarily in FIG. 13, the driver belt
system 176 includes a drive pulley 178 having a stepper motor belt
180 positioned on the pulley 178. The pulley 178 is attached to a
drive axle 182.
[0102] With reference now to FIGS. 4,6,13 and 15, the internal
components of the control box 164 include a stepper motor 184. The
stepper motor 184 can be a commercially available product. For
example, a stepper motor which the inventors have found to be
operable in testing of an exemplary gauge profile system 104 is one
which is utilized for low speed and low torque applications. The
motor also should have relatively high accuracy and high resolution
characteristics. In this regard, a torque, speed and power graph
for a stepper motor 184 which may be utilized in accordance with
the invention is illustrated in FIG. 7. With further reference
primarily to FIGS. 13 and 15, the gauge profile system 104, within
the control box 164, also includes an encoder 186. The encoder
receives signals on symbolic line 200 from the stepper motor 184.
These signals are digitally encoded and applied on symbolic line
202 as input to a microcontroller 188. The encoder signals applied
as digital input signals to the microcontroller 188 on line 202
provide various motor characteristic information, including
position information for the microcontroller 188. In a feedback
configuration, the microcontroller 188 also applies digital signals
on line 204 as input signals to the stepper motor driver 190. The
physical representation of the stepper motor driver 190 is
illustrated in FIG. 13, and the symbolic functional representation
is illustrated in FIG. 15. The digital signals applied from
microcontroller 188 on line 204 to the driver 190 essentially
comprise control signals for the driver 190 to appropriately
operate the stepper motor 184 so as to cause the thickness sensor
162 to traverse the sheet coil 10.
[0103] In addition to the foregoing elements, the gauge profile
system 104 also includes limit switches 192 which are located
outside of the control box 162 and are positioned adjacent the
clamps 158 and 160. The limit switches 192 operate so as to limit
traversal of the thickness sensor 162 along the lower belt and
slide arm 156. The limit switches 192 are conventional in nature
and commercially available. The limit switches 192, when actuated
by certain positions of the thickness sensor 162, operate so as to
apply digital input signals to the microcontroller 188 on symbolic
line 206. In turn, the microcontroller 188 will be responsive to
the digital signals from the limit switches 192 on line 206 to
generate appropriate digital signals on symbolic line 204 to the
stepper motor driver 190, so as to control the movement of the
stepper motor 184.
[0104] In addition to the foregoing elements, the gauge profile
system 104, within the control box 164, also includes a wireless
board 194. Serial digital signals can be applied in a
bi-directional manner between the microcontroller 188 and the
wireless board 194 on symbolic lines 208. For example, the wireless
board 194 may include a WiMicro Wireless Ethernet configuration
with designation number 802.11. The wireless board 194 can transmit
and receive signals on line 210, which is attached to the antenna
170 for purposes of transmission/reception of spatial signals to a
remotely located computer (not shown).
[0105] As further shown in FIG. 15, the microcontroller 188 is
appropriately connected to the ultrasonic thickness sensor 162 for
purposes of applying and receiving signals on symbolic lines 212.
These signals may be transmitted on lines 212 through RS232
communication interfaces. In this manner, control signals can be
applied from the microcontroller 188 to the thickness sensor 162,
while correspondingly, signals indicative of thickness can be
generated by the thickness sensor 162 and applied as input signals
to the microcontroller 188.
[0106] As shown primarily in FIGS. 8, 9 and 10, the ultrasonic
thickness sensor 162 is mounted to a linear bearing 216,
specifically illustrated in FIG. 8. The linear bearing 216 is a
conventional bearing having a channel 218 longitudinally extending
therethrough. A set of bearing plugs 220 are located on each of the
four opposing top, bottom and side surfaces of the linear bearing
216. The bearing 216 is utilized to appropriately move the
thickness sensor 162 along the lower belt and side arm 156. As
shown in FIGS. 9 and 10, each of the bearing plugs 220 is
configured so as to be threadably received within the surfaces of
the linear bearing 216. The actual bearing plug surfaces 222
provide bearing surfaces against which the lower belt and slide arm
156 will abut during movement of the thickness sensor 162. The
linear bearing 216 and bearing plugs 220 are commercially available
and may be obtained, for example, from Frelon.
[0107] During operation, the thickness sensor 162 is mounted onto a
sensor sled 224, primarily shown in perspective view in FIG. 11.
With reference thereto, the sensor sled 224 includes the previously
described linear bearing 216 having bearing plugs 220 with bearing
plug surfaces 222. Further, the linear bearing 216 includes the
channel 218 through which is received the lower belt and slide arm
156. The sensor sled 224 also includes a lower sled plate 226, onto
which the sensor 162 may be appropriately mounted. The sled plate
226 is secured below the linear bearing 216 through the use of
bolts 228, nuts 230 and a support plate 232 on which is mounted the
linear bearing 216. A clamp 234 is utilized to adjustably secure
the linear bearing 216 onto the lower belt and slide arm 156, with
the adjustability being with respect to the "tightness" between the
arm 156 and the bearing plugs 220.
[0108] FIG. 12 illustrates components of the end clamp 158. With
reference thereto, the end clamp 158 includes a stopper sleeve 236,
preferably having a rubber backing on the sleeve 236. Integral with
or otherwise connected to the stopper sleeve 236 is a sleeve
bracket 238 positioned below the stopper sleeve 236. The sleeve
bracket 238 has a right-angle configuration as illustrated in FIG.
12. The clamp 158 also includes an L-shaped bracket 240, also
preferably having a rubber backing The stopper sleeve 236 is
equipped with a stopper set screw 242 at the upper portion thereof.
A second stopper set screw 242 is also positioned at the lower end
of the sleeve bracket 238, and is utilized to adjust the relative
positions of the sleeve bracket 238 and the L-shaped bracket 240.
The upper set screw 242 can essentially provide for coarse
adjustment, while the lower stopper set screw 242 provides for fine
adjustment.
[0109] A convenient way for transporting the components of the
gauge profile system 104 is illustrated in FIG. 14. As shown
therein, the control box 164 can be enclosed with the cover 174. If
desired, the thickness sensor 162 can be secured to the control box
cover 174 through the use of backing, such as Velcro. Also, a lift
handle 244 can be provided.
[0110] The lap count system 106 will now be described in greater
detail, primarily with respect to FIGS. 5 and 16-18. With respect
first to FIGS. 5, 16 and 17, the lap count system 106 includes a
lap count system support stand 246. The lap count system support
stand 246 includes a lower support 248 consisting of several
components. More specifically, the lower support 248 includes a
series of four casters 250. Each of the casters 250 is rotatably
secured to a leg support 254 through a clevis 252, which permits
the corresponding caster 250 to rotate relative to the clevis 252.
Connected to or otherwise integral with the leg support 254 at the
center point thereof is a vertical leg 256 extending upwardly
therefrom. Positioned as desired along the vertical leg 256 is a
crank box 258. The crank box 258 can be operated and is
conventionally structured so as to move along the vertical leg 256
through a conventional rack and pinion configuration comprising a
conventional pinion gear 266 and rack 267 which is vertically
mounted along one side of the vertical leg 256. The crank box 258
includes a set of three sides 262. Extending through one of the
sides 262 is a conventional crank 260 which, in turn, is connected
to the pinion gear 266 through a conventional axle. Mounted to a
fourth side of the crank box 258 is a linear slide mounting 264.
The linear slide mounting 264 is connected through pins 268 to the
crank box 258 and to a linear slide 280. As shown primarily in FIG.
5, the lap count system 104 also includes a control box 270 which
can be positioned in any suitable manner on the lower support 248.
The internal components of the control box 270 will be described in
subsequent paragraphs herein. As further shown in FIG. 5, power is
supplied to the control box 270 as AC power 272 running through
power cord 274. For purposes of wireless communication to a desktop
computer or the like, the control box 270 also includes an antenna
276 connected to appropriate components within the control box 270
for transmitting and receiving spatial signals 278 from the
computer.
[0111] The linear slide 280 is extremely similar in structure and
configuration to the previously described linear slide associated
with the gauge profile system 104. More specifically, the linear
slide 280 includes a stepper motor 282 which can be utilized for
purposes of moving a set of sensing equipment 284 along slide arm
286. The sensing equipment 284, as previously described herein,
includes a distance sensor 288 and camera 290. For purposes of
insuring adequate illumination, a set of lights 292 is also
included with the sensing equipment 284. With the foregoing
configuration, the sensing equipment 284 can be moved vertically
along the slide arm 286 in accordance with the functional operation
of the motor 282.
[0112] FIG. 18 is a functional and partially diagrammatic
illustration of the various components of the lap count system 106.
With reference thereto, the control box 270 is shown as including a
micro-controller 294 which can be similar to the micro-controller
previously described with respect to the gauge profile system 104.
Bidirectional lines 296, comprising what may be RS232 and RS485
interfaces can be utilized to transmit digital power signals to a
servo amplifier 298, and to transmit and receive bidirectional
signals in the form of control signals. The servo amplifer 298 is
utilized to control the motor and encoder 282. The motor 282 is
controlled through the servo amplifier 298, and encoding signals
can be transmitted bidirectionally on lines 300 between the encoder
282 and the servo amplifier 298.
[0113] As previously described, the lap count system 106 includes
the ultrasonic distance sensor 288. The distance sensor 288 is
controlled by the micro-controller 294 through analog signals
transmitted as input signals to the sensor 288 on lines 302. Lines
302 are bidirectional in that signals can also be transmitted back
to micro-controller 294, indicative of the distance sensed by the
sensor 288.
[0114] In addition to the foregoing, and as also previously
described, the lap count system 106 includes a DVT area scan camera
290. The scan camera 290 is also under control of the
micro-controller 294 through signals transmitted as digital power
signals on line 304. Lines 304 are bidirectional and image signals
can be transmitted back to the micro-controller 294 on lines
304.
[0115] The lap count system 106 can also include a wireless router
306 which is commercially available and conventional in nature. The
wireless router can transmit and receive signals on an Ethernet
basis to and from the micro-controller 294. In addition, signals
can be transmitted from the router 306 and received by the router
306 to and from the antenna 276. These signals would initially be
in the form of spatial signals 278 transmitted to or received from
a remote computer (not shown). In addition to the foregoing,
signals can also be transmitted to and from the router 306 on lines
310 with respect to the camera 290. Finally, the control box 270
includes a power supply 312. With this configuration, and with the
functional operation of the lap count system 106 as previously
described herein, the average thickness of a coil can be computed
by counting the exact number of laps of the coil, as well as the
inside and outside diameters of the coil. With this information
combined with a width measurement, the volume of the coil can be
determined. With the volume combined with a weight measurement, the
average gauge of the coil can also be determined. In accordance
with all of the foregoing, and as shown in the drawings, a
three-dimensional gauge projection can be provided through the use
of the gauge profile system 104 and the lap count system 106.
[0116] If desired, and in accordance with certain concepts of the
invention, it is possible to utilize a processing algorithm with
respect to the images sensed by the camera 290. This is directed in
substantial part to detect the number of laps with as much accuracy
as possible. For purposes of detecting the laps, the algorithm will
look at the changes in light intensity across the width of the
image produced by the camera 290. Because of the vertical symmetry
in the image, such information can be taken from a relatively small
horizontal window. This fact allows an algorithm to take advantage
of the camera's partial image acquisition. That is, using partial
image acquisition, the camera 290 can capture and process a small
portion of the image. This reduces the amount of data that must be
stored in memory and processed, which decreases the time required
to process each image.
[0117] FIG. 19 illustrates an original image of the lap count as
produced by the camera 290. Correspondingly, FIG. 20 illustrates
the partial image acquisition process. Once the partial image has
been captured, it can be averaged along the columns (the columns
representing the laps) to produce a single roll of pixels
representative of the changes in light intensity across the image.
An example of such averaging is illustrated in FIG. 22, which shows
the result of the vertically averaged image from the original image
illustrated in FIG. 21.
[0118] In this regard, each pixel is represented by an 8-bit
grayscale value, where zero represents black and 255 represents
white. FIG. 23 illustrates a plot of the grayscale values along the
length of the averaged image. Each lap is visible as a peak in the
graph. The low areas in the graph are caused by the dark regions
between the laps, and the high areas are caused by the bright edges
of the laps.
[0119] The peaks, however, would be difficult to detect because of
the noise caused by imperfections in the surface of the sheet coil
10 and non-ideal lighting. In order to reduce the noise in the
signal, a low pass filter, conventional in nature, may be applied
to the data. The frequency component of the signal, along with the
low pass filter result, is shown in FIG. 24.
[0120] The filtered data is illustrated in FIG. 25. As shown
therein, the noise in the signal has been greatly reduced, and the
peaks can be easily counted with a set threshold. Also, the
location of each peak can be found relative to the edge of the
frame. It is important to note that the filter may introduce a
phase shift. However, because a finite impulse response filter is
used, the phase shift will be linear. Accordingly, the filter will
only create a delay in the signal, for which compensation can be
easily applied.
[0121] The camera can then transmit the peak locations within the
image to the computer. In a physically realized experiment, the
in-dash camera processing algorithm was implemented on the Cognex
535 area scan camera using the DVT Intellect software. The
operation of the algorithm was verified, in addition to the
camera's communications. Also, a preprocessing step was added,
which increased the contrast of the image. The camera was capable
of executing the entire algorithm from image acquisition to data
output at a rate greater than 40 Hz. This exceeds the desired 30
Hz.
[0122] With respect to post-camera processing, as the camera moves
along the side of the coil 10, it will transmit the peak location
to the computer. The computer will track the peaks as they move
through the field of view. As the peaks exit the frame, the
computer will increment a count. After traversing the entire side
of the coil, this count will be equal to the total number of laps
in the coil.
[0123] It has been found that in order for the computer to track
the laps, the camera must capture frames at a rate of at least
twice the rate at which the laps move through the frame. Because
the frame rate is fixed, the vertical velocity should be adjusted,
depending upon the gauge of the coil to guarantee that enough
samples are taken to properly represent the laps.
[0124] In addition to the camera algorithm, focus testing can also
be implemented. That is, any changes in the distance between the
coil sidewall and the camera may affect the focus of the captured
image. Depending upon the lens, lighting and shutter speed, the
camera will be able to focus at a set distance away, within a set
focal range. However, if the coil sidewall moves out of range
during a test, captured images may become blurry. To determine
focus capability, a damaged coil was photographed over the damaged
region. The resulting image is illustrated in FIG. 26. As shown
therein, the left-most portion of the image is in focus. However,
the right side of the image is out of focus because the damaged
laps have been pushed toward the camera. An algorithm was then
applied, with the results shown in FIGS. 27 and 28. Specifically,
it was shown that the algorithm was able to successfully count the
laps, even though certain of the laps were out of focus. In the
unfiltered averaged data, the left-hand side of the image that was
in focus had a relatively greater high frequency content. The
right-hand side that was out of focus had much less high frequency
content, and was smoother. However, even with the loss of this
data, the algorithm can easily identify out-of-focus laps.
[0125] As earlier stated, the gauge profile apparatus in accordance
with the invention can use a gauge profile system distinguishable
from the gauge profile system 104. A second embodiment of a gauge
profile system in accordance with the invention is described herein
as gauge profile system 400 and is illustrated in FIGS. 29-60.
Again, it should be emphasized that the resultant functions and
purposes of a gauge profile apparatus utilizing the gauge profile
system 400 is the same as a gauge profile apparatus using the gauge
profile system 104.
[0126] From the prior description, it is apparent that although the
gauge profile system 104 provides significant advantages over the
prior art, the gauge profile system 104 is somewhat complex and is
difficult to be handled by only one person. Unfortunately, steel
companies will often only have one person taking care of receiving
of steel coils. Further, as occurs with any mechanical invention,
the greater the number of moving parts, the higher the probability
of maintenance and repair necessities. Also, the track system
utilized with the gauge profile system 104, as a result of its
elongated configuration, may be damaged within the types of
environments which exist in steel warehouses.
[0127] As described in subsequent paragraphs herein, the embodiment
of the gauge profile system 400 provides a production-ready and
hand-held measuring device capable of measuring variations of the
thickness of the top layer of a steel coil from one edge to the
opposite edge, as well as the position from the leading edge of the
coil that each measurement is taken. The gauge profile system 400
provides for a relatively high precision in terms of measuring
thickness, while also providing a relatively wide range. In
addition, linear position measurements are also provided with a
relatively high precision, and with a relatively wide range. Of
particular significance, the gauge profile system 400 as used for
measuring the sheet coil 10 is preferably handled and relatively
easy to operate by one person. Also, the measuring process should
preferably take less time than known methods of measurement in the
prior art. Also, it is advantageous if the gauge profile apparatus
is able to store or upload measurements for further analysis. Still
further, and again with respect to the types of environments which
exist in steel warehouses, it is preferable for the device to be
able to operate in a relatively severe environment, including
temperatures which may reach 100 degrees Fahrenheit. In addition,
it is advantageous if the gauge profile system being used is
capable of interfacing with a computer or network so as to download
daily receiving schedules, as well as upload measurement data.
[0128] These and other advantages are provided by the gauge profile
system 400 illustrated in FIGS. 29-60. A perspective view of the
entirety of the profile system 400 is illustrated in FIG. 29. An
exploded view of the case assembly for the profile system 400 is
illustrated in FIG. 30 and individual component parts are
illustrated in FIGS. 31-44. The physically realized prototype has a
weight of approximately 6.4 lbs. Power is provided by a PDA
battery, while an embedded device of the system is powered from 4
rechargeable AA batteries. The system is capable of at least 30
minutes of continuous use, and employs an access door for fast
battery charges.
[0129] Measurement thickness tolerances are in the range of 0.0001
inches, while linear position resolution is 0.0169 inches, or 60
counts per inch. The range for material thickness is 0.01 to 0.75
inches. The linear position range is 0.25 to 82 inches. Further, in
accordance with the physically realized embodiment, internal memory
for a PDA was 192 MB ROM. An external memory with SD for back up
was also provided. Storage on a network was provided through a PDA
WiFi.
[0130] With respect to the user interface, a graphical user
interface with an LCD display was used. Button-type enabling
switches were utilized for various software functions. If desired,
a software keypad can also be provided on the PDA screen, for
purposes of identifying sheet coils. With respect to other
specifications, all tolerances were met with an environment of up
to 100 degrees Fahrenheit. Drop resistance was provided for up to 4
feet. In addition, the system 400 is preferably splash
resistant.
[0131] Turning specifically to FIGS. 29-44, the gauge profile
system 400 has a configuration as particularly shown in FIGS. 29
and 31, in perspective view. The gauge profile system 400 includes
a case cover 402 for protecting instrumentation within the severe
environment. A PDA 404 is provided, which can be conventional and
commercially available. An ultrasonic test 406 is also provided.
The entirety of the profile system 400 or case assembly 400 also
includes a rectangular-shaped top plate 408, with a cleat 410. A
control board 412 is also provided, with electronics associated
with the controller residing thereon. The profile system 400 also
includes the wand handle 414. In addition to the foregoing, strain
relief is provided by the strain relief device 416. Two power
switches are provided, identified as power switches 418 and
424.
[0132] As earlier stated, the profile system 400 can be powered in
part by internal batteries. The batteries are held through a top
battery clamp 420 and a bottom battery clamp 426. In addition, for
purposes of charging, a PDA charge connector 422 is also provided.
For purposes of indicating proper operation, a power indicator
light 428 is additionally provided. With respect to the strain
relief 416, a roundabout 430 is also provided and secured to the
strain relief device 416. As described in subsequent paragraphs
herein, the gauge profile system 400 also includes a string encoder
432.
[0133] In addition to the previously described elements, the
profile system 400 also includes a back plate 434. Magnets 438 are
provided for purposes of releasably securing the profile system 400
to a stand or the like, while not in use. Also, the magnets 438
provide for a means of releasably securing the profile system 400
to the sheet coil 10 to be measured, during operation.
[0134] The entirety of the profile system 400 or case assembly 400
is also shown in FIG. 31. FIG. 32 illustrates the case bottom 436.
Correspondingly, FIG. 33 illustrates, in perspective format, the
case bottom plate 440. The case top plate 408 and the case
roundabout 430 are further illustrated in FIGS. 34 and 35,
respectively. In addition, FIG. 36 illustrates a PDA standoff 444,
while FIG. 37 illustrates an Olympus standoff 446. The bottom
battery clamp 426 and the top battery clamp 420 are further
illustrated in FIGS. 38 and 39, respectively. In addition to the
foregoing, FIG. 40 illustrates the wand assembly 454, manually held
by the operator during use of the gauge profile system 400. The
wand assembly 454 includes the previously described wand handle
414. In addition, the wand assembly 454 includes the wand bottom
plate illustrated in FIG. 42, the wand main 450 illustrated in FIG.
43, and the wand cover 452 illustrated in FIG. 44.
[0135] FIG. 45 is a diagrammatic view illustrating the functional
and interconnected relationships among the lap count system 106, a
network 456 and the various devices associated with the gauge
profile system 400. Specifically, the lap count system 106 can
correspond to the lap count system 106 previously described in
detail herein with respect to the gauge profile apparatus 100. The
network 456 can include any conventional network to which the
appropriate data may be applied. A functional relationship between
a gauge profile system and a lap count system was previously
described herein and illustrated in FIG. 3. The functions performed
by the system illustrated in FIG. 3, using the average lap gauge
data from the lap count system 106 and the outside/inside lab
profile data from the gauge profile system will also be utilized by
the network 456 in the same manner. That is, the ultimate output
desired through the use of the gauge profile apparatus using the
gauge profile system 400 in accordance with the invention is an
average three-dimensional profile over the length of a sheet coil
10. As with the gauge profile system 104 previously described
herein, the gauge profile system 400 utilizes an ultrasonic gauge
device (i.e., the ultrasonic tester 406) for purposes of bombarding
the sheet coil material with high frequency sound waves. This
information from the tester 406 is applied through an RS-232
interface to an interfacing microcontroller board 412. The RS-232
interface from the ultrasonic tester 406 to the microcontroller
board 412 can have the following specifications: 19200 baud; 8
bits; 1 stop bit; no parity; and no flow control. Correspondingly,
the PDA 404 has bidirectional communication with the interfacing
microcontroller board 412. This communication is also provided
through an RS-232 interface, which may have the same specifications
as the interface between the ultrasonic tester 406 and the
microcontroller board 412.
[0136] Correspondingly, the string encoder 432 can be utilized to
connect to an encoder counter circuit (also on the microcontroller
board 412) through a 3-channel (e.g., A, B, Z) quadrature
interface. The encoder counter relays encoder counts to the serial
interface circuit through the use of a 16 byte data bus. In
addition to the foregoing, the PDA 404 may be utilized with the
network 456, through bidirectional transmission between the network
456 and the PDA 404 using an 802.11b wireless connection to a main
computer or the like for purposes of appropriate communications. A
corresponding wireless connection can also be made so as to provide
bidirectional communication between the lap count system 106 and
the network 456. Again, it should be emphasized that the data being
provided to the network 456 by the gauge profile system 400
corresponds to the same type of data generated by the gauge profile
system 104 previously described herein with respect to the gauge
profile apparatus 100.
[0137] In operation, the gauge profile system 400 will typically be
used by sheet coil receiving personnel for purposes of gathering
data to create a cross-section of the thickness of one layer of the
steel coil 10 from the leading edge of the coil to the opposite
edge. At the beginning of a day, the operator would likely remove
the gauge profile system 400 from a charger, and enable power. Once
powered, the gauge profile system 400 can be programmed so as to
automatically be connected to a wireless area network associated
with the operator's company. The gauge profile system 400 may then
be programmed so as to either automatically download daily coil
receiving information, or instruct the operator to download daily
coil receiving information from the network 456.
[0138] When a sheet coil 10 is received, the operator may take the
profile system 400 off of the charger and mount it to one side of
the sheet coil 10 using the magnets 438 located on the back side of
the case assembly. When the profile system 400 is mounted to the
coil 10, the operator can then select the correct coil ID and
measurement mode from drop down options associated with the PDA
404. When successfully completed, the operator can press the "gauge
test" button, so as to begin triggering measurements to be stored
in the PDA 404. When the operator is finished taking measurements,
the operator can press a "done" button located in the software
associated with the PDA 404. When the button is pressed, the PDA
404 will stop the measurement process, analyze the collected
measurement data, and upload the data and analysis to a specified
location on the network 456. When the gauge profile system 400 is
not in use, it is preferably plugged into an appropriate charger. A
sketch of the profile system 400 in use (absent the operator) is
shown in FIG. 46. Simulated image file information and data that
may be saved are illustrated in the representative screens of the
PDAs 404 shown in FIG. 47.
[0139] The linear measurement provided by the gauge profile system
400 is achieved through the use of the string encoder 432. Such
devices are commercially available. The underlying technology of
the string encoder 432 is a rotary encoder utilizing three signals
(i.e., A, B and Z). Signals A and B are generated 90 degrees out of
phase so as to indicate direction, while signal Z acts as a "home
pulse" (which indicates a full revolution). A shaft of the encoder
432 can be attached to a spool of stainless steel cable 458
illustrated in FIG. 46. As the cable 458 is unspoiled, the shaft of
the encoder 432 rotates, and A/B channels are pulsed in quadrature
(i.e., 90 degrees out of phase with respect to one another). Rising
and falling edges of the channels A and B can be interpreted to
increment (with the shaft turning clockwise) or decrement (with the
shaft turning counter-clockwise) the total number of encoder
counts.
[0140] Channel Z is used to confirm the total number of counts. The
encoder counts are interpreted as a linear position by multiplying
the total number of counts by the encoder's resolution. The
resolution is typically given in inches per count.
[0141] As earlier described, the gauge profile system 400 includes
the PDA 404. An example and commercially available PDA which may be
utilized as the PDA 404 is the HP iPaq Hx 2495 PDA. The PDA 404
acts as the major means of communication, storage and analysis for
data collected about individual coils from the linear and
ultrasonic measurement devices. The PDA 404 also acts as a user
interface to the measurement sensors and data which are stored on
the network 456. The operator can start a measurement from the PDA
404 by selecting the appropriate options and coil ID, and then
pressing a software button "start." The device can then wait for
serial data from the embedded device, which sends data in the
format of "distance, thickness" where distance is a linear distance
from the edge of the coil in encoder counts, and thickness is the
thickness of the coil at the linear distance in inches where a
measurement has been taken. After successful reception of data from
the embedded device, the PDA 404 can respond with an "*" to
indicate that it has successfully received and parsed the data. If
data reception was unsuccessful, the PDA 404 can respond to the
embedded system with an "X" so as to indicate that the data was not
received correctly, and that the embedded device should resend the
data. When the operator has completed coil measurements, the "end"
button can be pressed, and the PDA 404 can send the "end" command
to the embedded device, so as to let it know that it is no longer
accepting measurement data. This function can also indicate to the
PDA 404 to begin analysis of the data.
[0142] The data that has been collected can be compiled into a text
file and a "line of best fit" can be computed. The line of best fit
can be plotted with real data points, and saved as an image file.
Accordingly, both the text file and the image of the plot can be
uploaded to a specified location on the network for later review.
An example set of equations for the "curve-best-fit" analysis is
illustrated in FIG. 60, which also indicates the definitions of the
variables.
[0143] The interface microcontroller board 412 can include two
microcontrollers, associate control communications and encoder
counting. The board 412 can also act as a means for powering the
ultrasonic measurement device 406.
[0144] One of the microcontrollers can act as the interconnect
between the PDA 404 and the measurement devices, as well as
providing visual feedback to the user through the use of LEDs. This
microcontroller can wait for a start command from the PDA 404,
which can essentially notify the microcontroller to start the
measurement process with or without interval measuring enabled. If
the microcontroller receives a start command without interval
measuring enabled, then it will wait for and relay valid
measurements of distance and thickness to the PDA 404 without
indicating when the operator should take the measurements. If the
microcontroller receives the start command with interval measuring
enabled, it will wait for and relay valid measurements of distance
and thickness to the PDA 404, while indicating points at which the
operator should take a measurement through use of different colored
LEDs.
[0145] When the measurement process is initiated, the ultrasonic
measurement from the tester 406 will continuously send thickness
measurements at an approximate rate of 16 Hz. The microcontroller
412 can continuously parse this thickness data and determine
validity. If valid, the thickness measurement is relayed along with
the linear position to the PDA 404. This process will be repeated
until the microcontroller receives an end command from the PDA
404.
[0146] The second microcontroller can function as an encoder
counter, and may be clocked at a speed of 20 MHz, in order to count
encoder pulses as fast as possible. As earlier described, the
signals into this microcontroller from the string encoder 432 are
signals A, B and Z. The A and B signals are square pulses, where B
is 90 degrees out of phase from A (this is for purposes of
determining if the string or cable 454 is being pulled out or
retracted in). Signal Z is a home pulse to indicate that there has
been one full resolution. The encoder counts are relayed from this
microcontroller to the first microcontroller through a 16 byte data
buss. A reset line comes from the first microcontroller and is used
to reset the encoder count values.
[0147] The power supply circuit can include two subsystems. The
first can be a solid state power multiplexer designed to switch
between two possible power connections, namely USB buss power and
batteries. The second subsystem can be a voltage regulator.
Commercially available voltage regulators appropriate for these
purposes are available from Linear Technologies. The regulator is
configured in a SEPIC mode. This mode allows regulation of an input
voltage, in the range of 3 to 7 volts, with the output voltage at 5
volts. The regulator is necessary, since the USB voltage can range
both above and below 5 volts. The low battery indicator function of
the regulator is set up so as to drive low when the input voltage
drops below a particular threshold.
[0148] Serial interfacing can be provided at plus and minus 10 volt
levels. A logical multiplexer can be used to split the data
transmitted from the computing option. If the USB is connected,
then the USB port will be a primary mode of communication. The
interconnect board 412 will send data to both the serial port and
the USB port. If the USB port is not plugged in, then the
interconnect board will only receive data from the serial port.
[0149] The ultrasonic sensor 406 can use a delay line transducer
with a dry couplant so as to take thickness measurements of one
layer of the steel coil 10. The measurements can have a resolution
of 0.0001 inch. The measuring device will send thickness data to
the serial port at a predefined rate. The tester 406 essentially
works by transmitting an ultrasonic sound wave through the target
material, and analyzing the reflective wave to determine the
thickness. This concept of transmitting ultrasonic sound waves and
appropriate means for analysis to determine thickness were
previously described herein with respect to the gauge profile
system 104.
[0150] For purposes of further description and detail, the wand
assembly 454 is further shown in FIG. 49. The wand assembly 454 is
also shown in an exploded view in FIG. 50. FIG. 50 illustrates the
wand base or bottom plate 448, main 450, cover 452, delay line
transducer 459 and the strain relief 416.
[0151] FIG. 51 illustrates a block diagram for the serial relay
controller. The diagram is essentially self-explanatory. The
controller essentially waits for a command from the PDA 404. When
received, the command is processed so as to determine validity. If
the command is a start command, the gauge test is initiated and
thickness data and data counts are received and determined. More
specifically, thickness data and data counts are continued until
end signals are received. Correspondingly, FIG. 52 is a block
diagram for the end counter count controller. The diagram is self
explanatory, and essentially provides the functions of sequentially
making counts and determining when the counting process should
end.
[0152] FIG. 53 is a functional state diagram of the PDA software
which will be incorporated within the PDA 404. Again, it is
believed that this state diagram is self explanatory, but will be
set forth in greater detail in subsequent illustrations herein.
Essentially, following an initiation or start of the process,
function states include the addition of a new sheet coil 10, gauge
testing, processing of collected data, data transfer and the
importation of data files associated with the sheet coils 10. FIG.
54 illustrates a state functional block diagram for the start
command. Essentially, a screen is displayed for the operator, so as
to indicate start up.
[0153] Software information is then further displayed, along with
tags lists for the sheet coils. The operator may add additional
tags and then initiate testing. The state will also allow the
operator to visualize the plots of the collected tests and the
overall results. FIG. 55 is a state functional block diagram for
the "add new coil" state. In this state, the coils information form
that the operator must fill out is displayed. If the operator does
not discard or otherwise cancel the operation, the input
information is added to the database, and the list of selectable
coils is updated.
[0154] FIG. 56 illustrates a state functional block diagram for the
"input coils data file" state. This state allows the operator to
add a list of coils from the file. Again, if the operator does not
cancel the operation, the input information is put into the
database and the list of selectable coils is updated.
[0155] FIG. 57 illustrates a state functional block diagram for the
"gauge testing" state. In this state, serial commands are
transmitted to the appropriate microcontrollers so as to initiate
the gauge test for the selected coil. A "listen" operation is then
performed on the serial port, so as to retrieve the distance and
thickness measurement. If the operator cancels the test, the test
is stopped and the results are discarded. If the operator finishes
the test, the measurements are appropriately stored. FIG. 58 is a
state functional block diagram for the "data transfer" functions.
In this state, a TCP server is established, to which data is to be
transferred. The operator then selects a data file, and the data
file is transferred to the connected client. Correspondingly, FIG.
59 is a state functional block diagram illustrating the "process
the collected data" state. In this state, a computation is made of
the "best-fit" value. The data is then plotted and stored.
[0156] In accordance with all of the foregoing, a second embodiment
of a gauge profile system 400 has been described and illustrated
herein. Advantageously, the gauge profile system 400 can operate
with only one operator. Further, the gauge profile system 400 has
relatively few moving parts. Also, the profile system 400 is
relatively compact, thereby reducing the probability of damage when
used in relatively severe environments.
[0157] It will be apparent to those skilled in the pertinent arts
that other embodiments of gauge profile systems in accordance with
the invention can be designed. That is, the principles of systems
in accordance with the invention are not limited to the specific
embodiments described herein. Accordingly, it will be apparent to
those skilled in the art that modifications and other variations of
the above-described illustrative embodiments of the invention may
be effected without departing from the spirit and scope of the
novel concepts of the invention.
* * * * *