Unilux Adds 100% Knife-Circumference View and Level 2 Tie to EdgeTech
06/16/2015 - Unilux says it is raising the stakes in steel production by adding 100 percent knife-circumference viewing and a Level 2 connection to mill computer systems to the EdgeTech edge-trim inspection system to improve the ability to monitor knives for better trimming and coil-management efficiency.
EdgeTech combines high-speed, high-resolution video cameras with stroboscopic inspection lighting placed next to strip edges to monitor coil trim quality.
“Together, the upgrades provide more information in real time to help the operators of expensive, value-added processes make the immediate adjustments needed to maximize yield and profitability,” said Mike Simonis, president, Unilux. “The 100 percent knife-circumference view gives operators much more time to see the condition of knives on the pulpit and work sides of the coil, make adjustments to hold a specification and verify the results in real time.
“That’s critical on a PLTCM line, where a mill can have three coils backed up on a line,” he continued. “A knife crack can create a weak point that tears an edge, and that needs to be caught as soon as possible. Left undetected, the problem could lead to a web break that will require roll changes and disrupt production flow with unscheduled downtime. Being able to make adjustments or schedule maintenance to change a defective knife can save thousands of dollars. The economics are compelling in markets where profit margins are as tight as specification tolerances.”
As these actions are taken, the mill’s computer system can automatically capture images and permanently store all the information in customizable data packs as related to the coil and actions taken. This will enable mill personnel to use the mill computer system to easily locate a defective edge for more efficient re-trimming operation and verify all edges of all coils meet specifications when shipped to customers. Process engineers can also reference the data when developing solutions to specific problems and keep processes flowing.
“Inspection for the entire trimming process requires an all-inclusive visual inspection tool that helps a trained operator immediately see and correct a very small condition that could damage an entire coil or several coils in a matter of minutes,” Simonis said. “Every single coil can have a slight variation. The system allows an experienced operator to see those slight variations and adjust for them immediately.”
Additional EdgeTech upgrades include error log documentation, DVR-style image playback and review and vertical camera adjustment that enable operators to compensate for steel gauge changes that may slightly raise or lower the steel relative to the camera’s view, giving them full view of the edge.
Unilux inspection systems use strobe lights to visually freeze detailed images of edges and flat surfaces moving at full production speed. Images allow process operators, technicians and engineers to use their knowledge and experience to spot and determine the causes of defects and to implement repair solutions.
Unilux Inc., headquartered in Saddle Brook, NJ, has 53 years of experience in designing and manufacturing industrial surface inspection lighting systems for the printing, converting, packaging, metals, papermaking and textile industries. Unilux stroboscopic inspection lights range from handheld, battery-powered units for spot or narrow-web/strip inspection, maintenance and troubleshooting applications to fixed-mounted units capable of inspecting surfaces up to 12m wide. Unilux currently has sales representatives in 58 countries throughout the world along with five service centers. For additional information, contact Unilux, Inc., 59 North 5th St., Saddle Brook, NJ 07663 USA. Phone: 800-522-0801 (US only) or +1-201-712-1266 (Worldwide); Fax: 201-712-1366; email: customerservice@unilux.com Internet: www.unilux.com.
“Together, the upgrades provide more information in real time to help the operators of expensive, value-added processes make the immediate adjustments needed to maximize yield and profitability,” said Mike Simonis, president, Unilux. “The 100 percent knife-circumference view gives operators much more time to see the condition of knives on the pulpit and work sides of the coil, make adjustments to hold a specification and verify the results in real time.
“That’s critical on a PLTCM line, where a mill can have three coils backed up on a line,” he continued. “A knife crack can create a weak point that tears an edge, and that needs to be caught as soon as possible. Left undetected, the problem could lead to a web break that will require roll changes and disrupt production flow with unscheduled downtime. Being able to make adjustments or schedule maintenance to change a defective knife can save thousands of dollars. The economics are compelling in markets where profit margins are as tight as specification tolerances.”
As these actions are taken, the mill’s computer system can automatically capture images and permanently store all the information in customizable data packs as related to the coil and actions taken. This will enable mill personnel to use the mill computer system to easily locate a defective edge for more efficient re-trimming operation and verify all edges of all coils meet specifications when shipped to customers. Process engineers can also reference the data when developing solutions to specific problems and keep processes flowing.
“Inspection for the entire trimming process requires an all-inclusive visual inspection tool that helps a trained operator immediately see and correct a very small condition that could damage an entire coil or several coils in a matter of minutes,” Simonis said. “Every single coil can have a slight variation. The system allows an experienced operator to see those slight variations and adjust for them immediately.”
Additional EdgeTech upgrades include error log documentation, DVR-style image playback and review and vertical camera adjustment that enable operators to compensate for steel gauge changes that may slightly raise or lower the steel relative to the camera’s view, giving them full view of the edge.
Unilux inspection systems use strobe lights to visually freeze detailed images of edges and flat surfaces moving at full production speed. Images allow process operators, technicians and engineers to use their knowledge and experience to spot and determine the causes of defects and to implement repair solutions.
Unilux Inc., headquartered in Saddle Brook, NJ, has 53 years of experience in designing and manufacturing industrial surface inspection lighting systems for the printing, converting, packaging, metals, papermaking and textile industries. Unilux stroboscopic inspection lights range from handheld, battery-powered units for spot or narrow-web/strip inspection, maintenance and troubleshooting applications to fixed-mounted units capable of inspecting surfaces up to 12m wide. Unilux currently has sales representatives in 58 countries throughout the world along with five service centers. For additional information, contact Unilux, Inc., 59 North 5th St., Saddle Brook, NJ 07663 USA. Phone: 800-522-0801 (US only) or +1-201-712-1266 (Worldwide); Fax: 201-712-1366; email: customerservice@unilux.com Internet: www.unilux.com.
