SiPRO Training Presentation

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Contents

1. Safety – Radiation & Gauge

2. Measurement
3. Main components
2.1 Top Arm
2.1.1 Gulmay HV & X-ray Generation
2.1.2 X-ray Tube assembly
2.1.3 Chop Shutter
2.2 Back Arm
2.3 Bottom Arm
4. Peripheral components
5. Bachmann M1
6. Computer configuration
7. Calibration

2
Contents

8. Profile Measurement & Scatter

9. Alloy Compensation
10. Temperature Compensation
11. Supervisory Applications & Screens
12. Shape Measurement

3
1. Safety

Radiation & Gauge Safety

4
2. Measurement - Overview: Definitions

5
2. Measurement - Overview: Definitions

Informal Definitions
� Profile
Cross-profile: how the strip
thickness varies across the
strip (at right angles to the
process direction)
� Flatness (“shape”)
Flatness measures the ability
of a cut strip to conform to a
flat horizontal surface

6
2. Measurement - Overview: Profile definitions

Xl Xc Xp X Typical profile defects

r wedge

excessive
crown
negative
crown
w=0 w=
wmax
crown = Xc - (Xl + Xr) / 2
wedge = Xl - Xr
profile = Xp for w = 0 .... wmax d
relative profile = ( Xp - Xc) for w = 0 .... wmax
edge drop = d

7
2. Measurement - Principles

Rotating X-Ray Sources

Shutter

• Fan shaped X-ray beam

• Alternate beams on/off
Scanning • 2 views of complete strip –Stereo
Pyrometer
• Multi-Channel static detector
Array
• Sampling rate of 5 ms
• Detector data multiplexed for
transmission to MEC
• Integrated Scanning Pyrometer

8
2. Measurement - Edge Detection & Apparent Thickness

Source 1 Source 2

Detector Surface

Source 1 Thickness Profile

Source 2 Thickness Profile

9
2. Measurement - XDM-USB Interface Module - Overview

The XDM03-USB is a hi-speed USB 2.0 interface providing synchronised

data acquisition and control of the XDM-0x range of X-ray detectors

• Configurable digital front-end ensures alignment and

synchronisation of incoming data
• On board 128k FIFO
• High speed USB 2.0 interface
• Serial port for setting and read back of detector configuration

10
2. Measurement - XDM-USB Interface Module

• The LED indicator on XDAS-USB module has the

following meanings:

Green Unit OK (idle)

Green (flash) Unit OK (scanning)
Data buffer overflow (idle)
Amber USB software reset required to re-sync buffers
Data buffer overflow (scanning)
Amber (flash) USB software reset required to re-sync buffers
USB interface stalled
Red Unplug USB cable to power cycle the unit
System under reset
Red/Green (toggle) Check SP cabling / power supply
Un-programmed USB adaptor
Off Check cabling/power then program firmware

11
2. Measurement - XDM-USB Interface Module – Hardware
Connection

• The XDM-0x detector connects to the XDM03-USB device via the 18-
pin Molex connector - the pinout is as follows:

12
3. Main Components

EPOS

Colour
Main Printer
Electronic
Console Services
#1 #2 Boxes

Junction
Box
X-ray X-ray
Warning Source Source
Lamps

C-frame

Chiller

Calibration Unit

Distribution Detector Array

Box

CVTs

13
3. Main Components --- C-frame

Standards Magazine Chop Shutter Tube Assembly

Motor Drive

High Voltage Generator

Pyrometer

One continuous Detector array plus

Power supplies etc.

14
3.1 Top Arm

Motor and Scanning X-Ray Tube Assemblies

Gearbox for C- Pyrometer for
frame drive temperature
profiles

X-ray driver. Rotating Shutter (Chop X-ray driver.

Gulmay HV Shutter) and internal Gulmay HV
generator reference Standards generator

15
3.1.1

Gulmay HV & X-ray

Generation

16
3.1.2. X-ray tube assembly
Lead Shield

Shutter X-ray Tube

Pre-collimator

Final Collimator

u Each tube is fitted with a tungsten safety shutter

and collimator.
17
3.1.2 X-ray Tube and Collimator ( 225 kV Tube)

18
3.1.2 X-ray Safety Shutter

• Tungsten shutter on the underside of the tube mounting

plate.
• Driven positively into the beam by a strong spring for
safety.
• Micro switch to sense when the shutter is fully closed.
• Air solenoid to move it out of the beam
19
3.1.2 X-ray Pre Collimator

20
3.1.2 X-ray Final Collimator

21
3.1.3 Rotating (Chop) Shutter and Standards Magazines

AC Motor
Chop shutter sensor Closed Coupling Open
Shutter Shutter

Standards
Magazines

22
3.1.3 Rotating (Chop) Shutter

23
3.1.3 Rotating Shutters (Chop Shutter)

• Rotating shutter mounted underneath each X-ray

tube and collimator assembly on top of the
standards magazines.
• Linked by a central shaft and driven by an AC
motor at one end. 50Hz
• Each shutter is a tungsten cylinder with a slot
machined in it. Fixed 90 degrees out of phase
• Open when the slot is vertical
• Alternately turns each radiation beam on and off
every 5 milliseconds.
• Opto sensor to synchronise detectors with X-rays

24
3.1.4 Standards Magazine (Internal Samples)

Pneumatic solenoids Thickness Samples

25
3.1.5 Scanning Pyrometer

LSP-HD scanning head requires Ethernet connection to C-frame

SiproPyro Windows application TCP/IP connection

SiproMeas SiproPyro

SiproSuper

SiproData

SiproDet

Sipro Application Domain

26
3.1.6 Top Arm Ancillary Parts

• Air cooler to remove excess heat

• Drive motor and gearbox
• Electrical junction box

27
3.2 Back Arm

• Bolted to top arm and bottom arm

• C-Frame splits into three for shipment
• No components
• Heat shield can be mounted to it

28
3.3 Bottom
2(c). Bottom
Arm Arm

• 10 mm thick stainless steel

• Slot for X-ray beam
• Titanium and Aluminium
overall cover
• Water Cooled

29
3.3.1 Bottom Arm - X-ray Detector Array

30
3.3.1 Bottom Arm - X-ray Detector Array

Detector modules

Signal Processor board

Interface board

31
2(c). X-ray Detector
3.3 Bottom Arm Array

32
3.3 Detector Module – XDM04

• 32 channels groups
• Sensors in Peltier
cooled Aluminium
housing
• Electronics board
• 22 bit A-D converters
• Memory
• PLD control
• Serial readout
• Peltier power bus bar

33
3.3 Detector Array

• Up to 20 modules in a
standard housing -
3840 mm detection
length
• No gaps
• Easy to change
sensors or modules
• Dry air purge
• Water cooling in trolley

34
3.3 Bottom Arm Detector Sensor
8 scintillators per unit and 4
units per detector module

0.25mm
lead
shield
2.5mm

6mm
Multiplexing
Electronics

• Cadmium Tungstate scintillator

• Large area photodiode
• Conformal coating
• Eight channels
• 6 mm wide by 20 mm long by 2.5
mm thick

35
3.3 Detector Block Diagram

• All solid state

electronics
• Low voltage
• Daisy chain modules
• Peltier controlled
cooling to 6 degrees C

36
3.3 Detector Interface

37
3.3 2(c). Detector
Detector cooling
Cooling

scintillator &
diode hosing

Peltier

Heat

Water Flow

• Peltier is a heat pump

38
3.3 Detector Power Tray

+9 Volts Power Peltier

supply power
supply

39
3.3 Data Transmission

• Each PCB has an address header which sets its logical position in the
array
• During measurement the charge from each diode is simultaneously
integrated for 4 milliseconds and then held for 1 millisecond whilst each
PCB digitises its 32 elements
• The module data is then sequentially read out to the host computer in
the next 5 milliseconds whilst the analogue part is collecting the following
4 milliseconds data

All Detectors Convert All Detectors Convert

Det 0 transmit Det 0 transmit

Det 1 transmit

Det 2 transmit Det 2 transmit

40
4. Cooling

• Water jackets to shield against mill heat

• Normally fed from customer’s water supply but can
be from an additional chiller
• Closed loop chiller for cooling:-
- X-ray tubes
- Top arm air cooler
- Detector cooling bed.
• Single circuit from the chiller is fed to the services
box.

41
4. Cooling - Chiller

u A

42
4. Water and Air Services

u A

43
4. C-frame services

u A

44
4. Cooling Circuits

• Four Circuits
• X-Ray Tubes 1 & 2
• Air cooler
• Detector Tray
• Each Circuit
• Flow adjuster
• Visual indicator
• Flow sensor
• Filter

45
4. Air Supplies & C-frame Cooling Water

•C-frame water jacket supply

•Filtered and regulated air to:
•Shutterand standards
solenoids
•Pyrometer & X-ray Tubes
Windows
•Detectors via drier
•C-frame purge
•Waterpressure gauge and
reducer valve.

46
4. Power Distribution Box
Door mounted push
buttons, switches and
relays for
•C-frame
movement
•E-stop

•Shutter isolator

47
4. Electrical Junction Box

48
4. Main Console

49
5. Bachmann M1

Bachmann M1

50
6. M1 and Main Computer: Basic Configuration

51
6.
6. Major
Major I/O
I/O Functions
Functions

52
6. Major I/O Functions

53
6. Major I/O Functions

54
6. Major I/O Functions

LSP-HD scanning head requires Ethernet connection to C-frame

XMDPyro Windows application TCP/IP connection

55
6. Major I/O Functions

56
6. Major I/O Functions

57
7. Internal Calibration
160000

140000

120000

100000

80000

60000

40000

20000

0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

• Easy in principal
• Measure detector signals for known thicknesses.
• Curve fit and interpolate

58
7. Internal Calibration – Source 1

160000

140000

120000

infinity
zero
100000
I390
I800
I1390
80000
I3000
I4390
I6000
60000
I7390
I8000

40000

20000

0
0 50 100 150 200 250 300 350 400 450 500

59
7. Internal
6. Major I/OCalibration
Functions– Source 2
7. Major I/O Functions

140000

120000

100000
infinity
zero
I390
80000 I800
I1390
I3000
60000 I4390
I6000
I7390
I8000
40000

20000

0
0 50 100 150 200 250 300 350 400 450 500

60
7. Internal Calibration

• Can calibrate automatically against internal

standards.
• Problems Source

• Samples cannot be made perfectly flat and

uniform
Standard
• Both systematic and localised variations in
thickness
• Each detector gets a slightly different
calibration
• Poor profile measurement
• But very useful for initial setup, quick checks
and standardisation Detectors

61
7. External Calibration

• Calibrate against small external samples.

• Samples are scanned through the gauge on a
motorised calibration jig
• Mounted in a lead shield to eliminate scatter
• Each detector is calibrated against the same
thickness sample
• Samples are mechanically measured and UKAS
certified.

62
7. Calibration Samples

80mm

X.Xmm
Standard, 70x70mm
100mm

Aperture, 60x60mm

XXXXX-XX
Orientation corner, 12x12mm

63
7. External Calibration

• Sample is continuously scanned

through the gauge
• Software analyses each 5mS detector
readout to find sample position
• Each detector is calibrated in turn with
each source
• Approximately 7 minutes per scan
• Typicaly 2 hours to calibrate a range
• Up to to 3 ranges

64
7. External Calibration Data

External Cal. R1 S1

200000

180000 det_no
infinity
zero
160000
I800
I1200
140000
I1600
I2400
120000
I3600
Sig. Level

I4800
100000
I7400
I9600
80000
E722
E1182
60000
E1691
E2463
40000
E3694
E7450
20000
E9613

0
0 32 64 96 128 160 192 224 256 288 320 352 384 416 448 480 512
Det. No.

65
7. Standardise

• Measure internal standards when doing the external calibration.

• Measure them again before measuring strip
• Work out a standardise factor to apply to strip measurement.
• External calibration is done very infrequently

66
7. Calibration Modes and Uses

Calibration Mode When? Who or What? Why?

Standardize Each coil ­ Daily Operator / PCC Corrects drift

Full (external) Very infrequently Technician Accurate

calibration

Internal Infrequently Technician Allows initial

setup; checking

Reference Automatic, at Full Gauge Ties Internal Cal.

Calibration time to Full Cal.

67
8. Profile Measurement

Source 1 Source 2

Detector Surface

Source 1 Thickness Profile

Source 2 Thickness Profile

68
8. Edge Scatter

Source

Strip

Detectors

• Makes edges look thinner than they are

• Corrected with thickness dependent exponential function
• Magnitude is affected by edge location

69
8. Thickness scatter

• Pass-line calibration performed with minimal scatter

• During measurement radiation scatters from rest of strip (in the process
direction)
• Minimised by good collimation
• The amount scattered is dependent on the thickness of the strip
• Must be characterised by taking measurements
• Compare thickness measured with and without the scatter – sled ON and sled
OFF
• Measurements with sled should be thicker
• Straight-line fit applied

Detectors

70
8. Height scatter

• External calibration performed at given height (preferably pass-line)

• During measurement strip maybe at a different height
• The compensation is for the direct radiation scattered away from a given
detector
• The amount scattered is dependent on the height the strip is raised (higher
position should be thicker)
• Characterize by taking measurement data at various heights
• 2nd order polynomial fit applied
X-ray
source

Strip

Detectors

71
8. Strip scatter

• Minimised by good collimation

• Usually only apparent on wide thick plates
• Seen as a dish shaped affect – thinner in the middle
• Further away from the centre, less scattered radiation in
• Not often used, values need to be entered directly into the scatter.ini file

X-ray
source

Strip

Detectors

72
9. Alloy Compensation

Alloy Compensation

73
10. Temperature Compensation

• Density reduces as temperature

TEMPERATURE T (oC)
increases, so material appears

T thinner to X-rays
E
M
P.
C • Temperature Index (TI) is analogous
O
M
P.
to AI
I
N
D
E
• TI equals twice the linear expansion
X
T
coefficient
I

• Typical TI for aluminium is ca. - 3% at

5000C

• Typical TI for carbon steel is ca. - 3%

t(%) at 10000C

74
11.Supervisor Applications & Screens

Supervisor Screens

75
11. Supervisory Application

• SUPERvisor application named SiproSuper

• Technician HMI virtually unchanged
• Enables transfer of data classes over Ethernet
• Directory structure changes

76
12. Shape

Edge wave Centre buckle

Poor shape means the strip is not flat
Edge wave caused by rolling edges longer than centre
Opposite for centre buckle
Measured by analysing height variation with time

77
12. Angle Measurement

If the strip is flat across its width both source thickness measurements
are the same (A).

• If angled then one source measurement is thin,

the other is thick (B).
• We can calculate the angle from the difference
between the two source measurements.
• The transverse gradient of the resultant R is a
measure for the angle at that spot.
The transverse gradients for all 5 mm spots of a
cross profile are calculated.

78
12. Contour From Angle

Calculate angle every

5mm across the strip
Polynomial fit to the
results
Integrate the angle
polynomial to give a
height polynomial
Fix the ends of the height
polynomial to the strip
edges

79
12. Contour Calculations

1 2

• First calculate angle assuming straight line between edges

• Then calculate contour
• Then repeat using calculated contour for new angle calculations
• Twice is enough!

80
12. Contour Corrections

• Correct thickness profile

• Correct width

81
12. Shape Measurement

Take a thread every 50mm of strip

width
From the strip contour, store the
height of each thread every 10
milliseconds
Also store strip speed and
calculate distance
Analyse the height variations with
distance
Calculate length of each thread
Shape for a thread is actual length
against flat length

82
12. Calculation of Shape

540
535
530
525
520
515 dS
510
505
500
0 1 2 3 4 5 6 Process
7 direction
8 9 10

• Shape for each “thread” can be calculated from the differential

length of the strip along the thread. [This is the length of the
thread if it was cut out along the length of the strip and allowed to
lay flat]
• Expressed in I - Units

� �L � �S �
I � � � � 10 � � � 1� � 105
5
� L� �L �

83
12. Symmetric and Asymmetric Shape

• Symmetric Shape
• Difference between centre and mean of
edges
• Positive means centre buckle
• Negative means edge wave
• Asymmetric Shape
• Difference between two edges
• Both easily visualised

84
 Thanks for your attention !

Questions ?

85