• Metal Newsletter March 2012
  • Metall Newsletter März 2012
  • 金属期刊 2012 年 3 月

Metals Newsletter March 2012


The NEW Standard of Quality Control for Steel and Aluminium from the worldwide leading Supplier of Surface Inspection Systems
The NEXT generation of surface inspection

The SURFACE MASTER product line not only assures best possible surface inspection solutions but also optimizes the entire flat steel and non-ferrous metals manufacturing process at highest system availability.

With the introduction of the SURFACE MASTER product line, a major step has been taken to empower our customers to improve their processes and quality. The user obtains highly efficient systems, available at more than 99,8%.

With the increase in worldwide competition, steel and non-ferrous metals manufacturers must be able to reliably monitor each and every production step. Over the last years, when it came to meeting this task, global players have turned to ISRA VISION PARSYTEC for the most capable surface inspection systems.
ISRA VISION PARSYTEC has leveraged its application experience, imaging and classification know-how and surface inspection focus and with close collaboration with its customers has developed the latest generation of surface inspection systems – the SURFACE MASTER product portfolio.

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Worldwide UNIQUE core Module:
the multi-stage Classification Technology

The system is delivered with the industry leading Instant ClassifierTM, immediate value is realized at start-up. A multi-stage classifier can be implemented for line specific defects – first self learning tools are employed and post processing tools can be used to combine defects into a logical result. The highest value is achieved with accurate detection and classification rates.
The advantage: All surface defects are reliably categorized and classified in an intuitive easy manner.
The result: the ability to reach the highest possible performance in the shortest amount of time.
The detection and classification results are used to trigger alarms for immediate corrective actions for process improvement.

STANDARD and high quality:
the Technology Components

Only the latest proven, high-quality hardware components are used in SURFACE MASTER systems. The fastest camera technology and the ability to combine matrix and line cameras for optimum image acquisition and the highest resolution and image quality provides the foundation for the next steps- reliable defect detection and classification.
Worldwide unique for hot rolling processes: the very latest, high-intensity focused LED illumination technology employed to optimally illuminate the surface with low maintenance.
The most powerful technology available on the market: The computer technology used for processing images, coupled with the network capabilities. Combined with the bundled range of highly developed algorithms from a number of different applications, the systems reach unparalleled performance levels in their ability to detect defects.

FASTEST Implementation and
OPTIMUM maintainability

"Time is money" – this is particularly true in the flat steel and non-ferrous metals manufacturing industry. This is why the ability to easily integrate the inspection systems into the production environment is such a critical argument. With over 400 metals surface inspection systems, SURFACE MASTER systems provide the latest design for the simplest line integration requiring less space and simpler electrical integration. The benefit is also extended to simple troubleshooting, maintenance and service.
After integration, the startup process is short. The system is delivered ready to go for any standard application- reducing the implementation time required by 50%. This saves resources and accelerates value and payback.

UNIQUE Calibration and Validation Tools:
Sensors and measuring components are calibrated precisely to assure accurate quality diagnosis. These calibration options represent a definite added value for the steel and non-ferrous metals manufacturer: He can count on his products passing the quality inspections of its customers with ease.

Many added functions – such as width measurement, quality data archiving or analysis software for structured surfaces – make the SURFACE MASTER products a universal tool for improving quality.
The new reporting and analysis tools in the SURFACE MASTER product line present online trends and important results of not only the surface inspection, but also the entire production process. Meaningful reports provide information about the quality of the produced coils, system diagnostics and ability to integrate additional process quality metrics besides surface data. Additional, knowledge-based decision-making tools are offered in the EXPERT5i software library which turn data to decisions saving time and eliminating unprofitable work.

TOP-OF-THE-LINE Innovations in the Product Line
The SURFACE MASTER portfolio is complemented by additional innovations such as the QMS quality management system.

Get more information about QMS in the following article.

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Great success at METEC this year:
Company-wide planable quality for steel producers

Quality Management System QMS
– Making your processes transparent!

QMS is a real time quality monitoring and alarming solution that works on individual production lines, on several consecutive lines and even throughout the entire company.

Based on the information supplied by QMS, steel manufacturers are able to immediately optimize multiple processes. Not only is surface inspection data utilized but all process data can be synchronized for easy analysis, corrective action and reliable decision making for production planning and optimization.

QMS- the next generation in quality management
In addition to quality, efficient processing to maximize production is the total combination required to succeed in the competitive global steel market. The quality management system -QMS is the solution that makes it possible to maximize quality AND optimize production, assuring cost savings and higher profitability.

What does QMS have to offer?

  • Reliable, exact quality analysis
  • Defect statistics, trends, reports and development

QMS provides a complete quality analysis not only for surface quality but for all quality metrics. It allows real time alarming for any metric (flatness, shape, outside of user defined limits for immediate corrective action. These defect tolerances are product or coil-specific and can be defined for each end customer separately and stored as a recipe.

Intelligent decision-making tool
QMS can be the critical link between the planning department, production and quality management. It performs in the role of a production assistant, providing intelligent tools needed in the decision-making process. To accomplish this, the QMS system accesses all available production relevant data as well as supporting data from any database companywide and creates a single synchronized view of all of the quality data.

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QMS analyzes and weighs the information and then generates knowledge-based solution proposals for decision-makers.

The clou: if any set rules are violated within certain segments or in the entire coil, alarms are immediately triggered, allowing the operator to take corrective action. The operator can positively impact the process by eliminating problems immediately and effect the quality level produced.
QMS, when used on several consecutive production lines, quality information is immediately available for each coil for each process. Surface quality information for each process is combined and synchronized to determine the development of defects along the process chain.

QMS field of application: single lines or several consecutive lines. Surface quality information for each process is combined and synchronized to determine the development of defects along the process chain. The ability to view what happened to a specific coil in previous processes empowers operators to systematically improve quality. Based on the statistical analysis of all process metrics processes and product quality can be analyzed and the highest metal quality can consistently be maintained.
QMS can be employed throughout the entire company. This makes it possible to set company-wide quality benchmarks from one production line to the next. This can optimize production planning. Production supervisors, for example, can make decisions about which line is best suited to produce which coil.

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Advanced quality diagnosis for slabs
First 3D Inspection worldwide for high-quality flat steel

3D inspection is a new generation of surface monitoring systems being used for the first application for slabs in steel production.

The 3D information enables detection of additional characteristics of defective structures, an even more reliable assessment of quality and classification of defects. False alarm can almost be totally prevented, leading to significant optimization of the entire steel production process.

Defect detection at an early stage
It is essential for manufacturers of high-quality steel to detect as many defects as possible upstream which only become visible in the following production steps of flat steel - in particular for cold rolling. The early detection of all relevant defects on the slab saves production expense, reduces costs, and prevents from wasted processing steps and rolling mill faults. The slab surface contains important information about serious defects. If these are detected, the slabs can be repaired by grinding or scarfing. Non-reparable slabs are sorted out immediately.

Capturing synchronous 2D and 3D surface information
Detailed inspection of faults is a special challenge as the slab surfaces defects have a great variety of appearances. These are caused by:

  • strong topographic and colored structures
  • harsh environmental conditions with temperatures up to 1,100 °C
  • water and steam
  • scaling, covers the damages on the slab and creates surface structures, easily confusable with specific defects
  • certain cracks are only found after the slab’s cooling

Simple contrast-based defect detection solutions therefore are less efficient.

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The new technology now ensures optimum defect recognition using complementary 3D inspection data. 2D and 3D surface information is recorded synchronously. Additional topographic information is generated at each pixel of a 2D surface image. Linked together through the application of a 3D measurement method, it provides additional data about optical and geometric properties allowing an even better slab quality grading. The inspection software takes into account the elongation of the material in the rollers, so that close examination is possible.

Highly accurate defect classification
Use of the 3D information for additional properties of surfaces and fault structures ensures highly precise fault detection by the Instant Classifier. False alarms are avoided, even if there are very pronounced structures. This is assured by highly efficient software algorithms.
Customers can add value and sustainability through inspection and process optimization with smart tools deployed along the entire production chain.

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Strengthened know-how in China
Intensified customer focus on the Chinese metals market

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The Chinese market is becoming increasingly important for ISRA VISION PARSYTEC. In order to respond to the growing importance of the Chinese market and to support it even more intensively, new customer support specialists have been hired for the metals industry in China.

In order to respond to the growing importance of the Chinese market and to support it even more intensively, new sales consultants have been hired in Shanghai. Thereby, the ISRA team in China has been expanded and strengthened, and the international sales activities increased.
With this expertise of the metals industry, it is possible to ensure the best possible on-site customer service. Systematic, local support makes it possible to implement projects quickly and to commission individual systems without delay. For ISRA VISION PARSYTEC, the permanent expansion of its sales network is an important pillar of its global company strategy. In total, the ISRA Group already employs more than 50 people in China.

The Customer Service & Support Center (CSSC) supports the customer at a local level. Thus the optimal use of systems and equipment is ensured. Furthermore, customer service is provided far beyond the successful installation of the equipment: Productivity is systematically increased.
ISRA VISION PARSYTEC assists the manufacturers in China further on the automation of their production processes and helps reducing production costs significantly. The customers benefit from highest profitability and quality improvement. In this way they ensure decisive competitive advantages.

On the safe side –
Worldwide assistance… anytime!

The Customer Support und Service Centre increases the machine uptime:

  • Optimum on-demand response
  • Reduced mechanism failure
  • Minimized customer complaints
  • Maximized equipment availability

Because: Modern equipment and highly engineered production processes with 24 hour operation require excellent service.

We support you: 24 hours/day… 7 days/ week… 365 days/year!
Help Desk – Worldwide: +49 (0)700 ISRA VISION (477 284 7466)
Help Desk – China: +86 (21) 6891 6963

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