Massive Cognex inspection application in Belgian steel plant

Citation

(2004), "Massive Cognex inspection application in Belgian steel plant", Sensor Review, Vol. 24 No. 1. https://doi.org/10.1108/sr.2004.08724aaf.008

Massive Cognex inspection application in Belgian steel plant

Massive Cognex inspection application in Belgian steel plant

Keywords: Machine vision, Steel, Cognex

Vision system detects and checks the correct picking up of pig-iron and steel pans with an intelligent camera at Sidmar plant.

At the production site of Sidmar in Ghent, Belgium, Cognex vision systems inspects the correct picking up of pig iron and steel pans. The vision system is known as one of the most clever automatic inspection systems in Benelux and is based on a Cognex vision system that checks the positions of the hook and the pan before it can be safely hoisted (Plate 6).

Sidmar is an incorporated steel processor and is situated on the west bank of the Gent-Terneuzen canal. Sidmar belongs to the Arcelor group, the largest steel producer in the world, which employs over 110,000 people.

Plate 6 Cognex vision systems are employed at the Sidmar production site

The products from Sidmar are especially used in the automotive industry but also other sectors that require high quality steel such as white goods, furniture, metal beams, radiators, barrels, pipes and construction industries. All these products are manufactured using high- level automatic production process and the very best techniques and technology available. As Sidmar intends to be more than just a producer and supplier of steel, it is continually looking at safety, quality, environmental conservation and cost effectiveness. These are the top priorities for Sidmar and the implementation of new technology in these areas is imperative to the companies continued success.

With these priorities in mind, in mid – 2002 Sidmar looked to improve the safety level at a vital point in the production process of pig iron into steel. Specifically where the filled cast pans with 400 tons of liquid pig iron at 1200° C are picked up and hoisted. The existing set up offered the risk of incorrect grabbing and hoisting was difficult to estimate because of the complex position of the crane driver in relation to the cast pan.

To reduce the risk of miss picking and hoisting of the pan to a minimum, Sidmar looked to increase the control of the hoisting point at the tap hooks when picking up the pig- iron or steel pan so that they are always grabbed correctly.

The extreme conditions such as the very high temperatures and dust to which the control system is exposed during hoisting, limited the possibilities for the use of ultrasonic or laser systems. Having gained valuable experience with Cognex vision systems in Sidmar's own rolling mill, the new solution incorporated orientated Cognex vision systems. These offered the outdated control system – which consisted of visual control, a monitor and a defined checkpoint – the required adjustment. Implementation of intelligent Cognex In-Sight 1,000 cameras and the PatFind training system completed the new set-up.

In the new updated set-up, a Cognex In-Sight camera is located at every detection point, on each side of the cast pan. These check and control the position of the hook in relation to the pick up axle of the pan. The new solution checks the distance (both x and y co-ordinates) between the centre of a white circle, painted on the pick up axle of the pig-iron or steel pan and the centre of a rectangle, painted on the tap hook. When the distance between the painted shapes is more than the accepted defined norms, the lifting movement is stopped.

The lifting movement is also interrupted if one of the cameras is damaged, or if there is any problem with the control system controlling the vision systems. Error messages are centrally passed on to a PLC in the control room.The In-Sight 1,000 vision sensors are equipped with all vision software tools pre-installed. Like other In-Sight vision sensors, they are built-in Ethernet communications, a full library of proven Cognex vision tools for locating, inspecting, measuring, and identifying parts, and a spreadsheet interface for fast, easy application set up. The sensors can be easily integrated with PC-based factory automation devices via Ethernet communications, and with PLCs on the factory for improved real-time vision data, system integration and the possibility to control and monitor activities at a distance.

In order to adhere to Sidmars policy of continuous improvement, Sidmar evaluated its production process and came to the decision to integrate an automatic inspection system to improve safety. The Cognex machine vision system became an integral part of that automated solution.

For further information, please contact: Leigh Simpson, Cognex UK Ltd, Sunningdale House, 43 Caldecotte Lake Drive, Caldecotte, Milton Keynes, Buckinghamshire, MK7 8LF. Tel: +44 (0) 1908 206033; Fax: +44 (0) 1908 392463; E-mail: lsimpson@cognex.com