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Surface inspection of aluminium strip products Presentation at ISIS.2011
Thomas Nenner (K. Moritz, V. Saß and J. Schwarz)
24.03.2011
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1 Introduction Hydro Aluminium Rolled Products
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A leading integrated aluminium and energy company
Primary Metal
1) Close March 1, 2010
Rolled Products
Energy
●20 000 employees
●Operations in 40 countries
●Turnover ● 2007: NOK 94 billion, Euro 11.7 billion
● 2008: NOK 89 billion, Euro 10.8 billion
● 2009: NOK 67 billion, Euro 7.6 billion
●Underlying EBIT ● 2007: NOK 9.9 billion, Euro 1.24 bln
● 2008: NOK 6.0 billion, Euro 0.73 bln
● 2009: NOK (2.6) billion, Euro (0.30) bln
●Market capitalization ● NOK 49 billion, Euro 6.1 billion1)
Metal
Markets
Extruded Products
Extruded Products
Metal Markets
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Rolling Mill Sales Office
Sao Paulo
New York
Malaysia
Karmoy
Holmestrand Stockholm
Barcelona
Paris
Cisterna
Krakow
Slagelse
Neuhausen
Huizen Hamburg
Norf/GV
Wolverhampton
Hydro - a key player in rolled products
●We operate leading rolling assets, foremost in Europe ● 6 plants in 4 countries
+ Alunorf, the world´s largest
aluminium rolling mill (50%)
●We employ around 4,000
●We ship up to 1 million tonnes per year ● 77% to customers in Europe
● 17% market share in Europe1
1 Estimate based on EAA data
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We serve a wide range of applications
Litho ● Plain strip and sheet for offset
printing plates
Packaging and building ● Plain and lacquered strip for cans
and other packaging containers
● Plain and converted foil for flexible packaging and technical applications
● Plain and lacquered strip, sheet and plate for architecture: Facades, roller shutters, etc.
Automotive, heat exchanger and general engineering ● Plain, anodised and cladded strip
and sheet for ● cars, transport and heat exchanger
systems
● general engineering, solar technology and special industry
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2 Surface inspection requirements of aluminium strip
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Surface inspection requirements Typical process route in aluminium strip production
Slitting
Coil coating
Lithography
…
Typical: Inspection of finished products
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• “clean” primary production and casting process
• often small defect size
• usually low risk of damaging production equipment by surface defects
• typical defects not visible for human inspectors due to high line speeds
SIS usually installed at last process step where they are most effective to:
• shield customer from defective material
• support release / blocking decision
• control complex finishing processes, e.g. coil coating
Conditions for inspection of aluminium strip:
Surface inspection requirements Inspection conditions
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• highly reflective surface
• wide range of products and surface appearances
• often extreme demands on surface quality (e.g. lithographic sheet)
• integration of SIS in existing complex and often unique processing lines
• need to develop dedicated classifiers for each SIS installation
Challenges in aluminium strip inspection:
General requirements:
• excellent detection and classification performance
• low requirements for user training and classification
• easy integration into existing IT infrastructure
• high reliability and low maintenance cost
Surface inspection requirements Challenges and requirements
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Challenge surface quality – Lithographic sheet:
Detection of geometric defects of only a few µm depth or height
Dent:
Ridge:
Surface inspection requirements Challenges and requirements
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Challenge integration in existing lines:
A slot had to be cut in the concrete hall floor to allow inspection of
bottom side on large diameter roll
Cameras bottom side
Cameras top side
Basement
Surface inspection requirements Challenges and requirements
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Overview of Hydro´s SIS installations:
Hydro´s SIS strategy:
• Installation in process step where SIS is most efficient for the customer
• Selection of best solution for each individual application
• Local departments responsible for SIS operation
• Sharing of Know-how and experience in internal networks
Manufacturer Installation Main products
Parsytec 1997 / 2008 Lacquered can stock
E+L 2005 Lithographic sheet
Cognex 2009 Brazing sheet
Cognex 2009 Painted packaging sheet
Cognex 2009 Automotive sheet
Cognex 2010
Lacquered can stock /
architectural sheet
Surface inspection requirements Hydro´s SIS strategy
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3 Surface inspection at BLA4
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Surface inspection at BLA 4 layout of coil coating line 4
Pretreatment
Oven
Degreasing Levelling Coiling Station
Floating Oven Coating Station
Inspection Waxing
Technical line data:
Line speed: max. 300 m/min
Strip width: max. 2080 mm
Stand. strip thickness: 0,20 – 0,50 mm
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Surface inspection at BLA 4 typical defects (SIS 1997)
Dark field
strong lamination
Dark field
Scratches in raw
material
Dark field
foam
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Surface inspection at BLA 4 typical defects (SIS 2008)
Line Field
foam
Bright Field
lacquer
spillings
Bright Field
softener spot
Line Field
rolled in dirt
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Bright Field
foam
Line Field
foam
Surface inspection at BLA 4 typical defects (SIS 2008)
Line Field
dent
Line Field
soil from oven
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Surface inspection at BLA 4 SIS 1997 vs. SIS 2008
SIS 1997 (CPU) SIS 2008 (CPU)
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Surface inspection at BLA 4 SIS 1997 vs. SIS 2008
SIS 1997 SIS 2008
max. speed 350 m/min. 450 m/min.
System Structure Standard Architecture: - 1 Multi-CPU-Computer per Camera (PCs) - 1 Frame grabber per Camera - Analog Video Capture
Simplified architecture: - 1 Compact-PCI per several cameras (3) - no Frame grabber - Digital Video Technology, Ethernet
System size 6 large racks required 1 medium rack only
SIS 1997 (CPU) SIS 2008 (CPU)
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Surface inspection at BLA 4 SIS 1997 vs. SIS 2008
SIS 1997 SIS 2008
Sensor type Combined BF + DF (both diffuse)
Matrix (diffuse light) + Line (direct light)
Camera type Analog cameras Digital cameras: increased - sensitivity, - contrast, - S/N ratio, - linearity
# cameras 24 DF Matrix 12 BF Matrix
24 BF Matrix 10 BF Line
resolution DF: 250/ 500µm BF: 750/1500µm [CD/MD]
250µm CD (both)
Illumination IR DF Matrix HQI BF Matrix
LED for both
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Surface inspection at BLA 4 SIS 1997 vs. SIS 2008
SIS 1997 SIS 2008
Classifier Builder Parsy Classification tool CBE: visual tool, intuitive and work flow oriented
System access User Interface ODIS + control panel
ODIS + control panel; Additionally: Web based access for results and remote diagnosis
# defect classes 65 (16 groups) 65 (16 groups)
# defect/coil 2.000-6.000 2.000-6.000
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Surface inspection at BLA 4 integration in production process
Inspection area
„public side“
Inspection area
„product side“
Material flow
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Surface inspection at BLA 4 integration in production process
Inspection area
„product side“
Online SIS
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Surface inspection at BLA 4 integration in production process
Online SIS
Coil report
Inspector
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Surface inspection at BLA 4 integration in production process
Online coilmap containig information for the inspector
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Surface inspection at BLA 4 integration in production process
●Inspection area with Online SIS for supporting the inspector
●SIS is suggesting the defect class
●Defects are displayed in different colors depending on the importance
●For each coil a coil report with detected defects is manually filled by the inspector
●Inspector is able to stop the process in order to inspect the surface
●Inspector suggests whether a defect causes scrap or not
●Foreman is using the Offline SIS for evaluation of defects
●Foreman decides whether parts are scrap or have to be inspected at the slitter
●Usage of SIS for estimation of claims
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Surface inspection at BLA 4 benefits of SIS upgrade
●better detection (sensor different to old system)
old system: bright field and dark field, different resolution
today: bright field matrix and bright field line scan, same resolution
●hardware is state of the art, spare parts available, most modern camera technology used
●simplified architecture: no camera PCs, no frame grabber; Ethernet communication
●much less maintenance required: strongly supported by Diagnosis Monitor, Remote Diagnosis, Online Doku
● less power consumption
●easy system tuning: detection tuning with sliders, classifier can be easily build by own operators (by means of CBE)
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Surface inspection at BLA 4 benefits of SIS upgrade
●software updates & upgrades available
●easy data archiving and backup
● integration in factory network, data access from offices e.g. with web tools
www.hydro.com