TubeProfiler 3D

Tube mill gauge - measurement of the dimensions and true shapes of tubes

Overview

The LIMAB TubeProfiler 3D is a mill gauge for measuring the shape and diameter of hot or cold rolled tubes or pipes. The TubeProfiler 3D measures the profile directly lasers profile sensors that simultaneously capture the true cross section, outer diameter, shape and ovality. The system not only provides very accurate measurement but is almost free from regular maintenance. Reliable and accurate measurements provide rolling mill operators with instant feedback on the tube shape and dimensions. Reducing mill set-up times and providing better yield from new or existing mills. The TubeProfiler 3D is proven and used by many of the best know quality steel producers.

Quick Spec

Diameter range Resolution No. of axes Product temperature
20-1600 mm 0.01 mm 4-12 0-1200°C

Operating Principle

The TubeProfiler 3D uses a number of LIMAB ProfiCura 2D laser sensors. These sensors use the principle of laser plane triangulation and are mounted on a circular base plate with the lasers directed to the centre. Each laser precisely measures the profile of a segment of the circumference and by combining the profiles of all the sensors a complete 360-degree profile of the tube or pipe is measured.

Applications

  • Hot tubes diameter & ovality measurement on a Pilger mill
  • Diameter and shape of welded tubes
  • Cold round tube diameter & ovality inspection
  • Measurement of hot or cold round or square bars in a rolling mill environment
  • Measurement of blooms and billets

ProfiCura 2D laser technology

The TubeProfiler 3D uses LIMAB’s standard ProfiCura 2D laser triangulation sensors which are a product of almost 30 years experience of producing precision laser sensors. The ProfiCura 2D sensors are robust, rugged yet very accurate and stable lasers and are at the heart of the TubeProfiler 3D.

No hidden shadows – full profile detail

Most traditional mill gauges use either camera or laser micrometer shadow scanners to measure the diameter or dimension of the product. The big drawback of this technology is that only the maximum dimension is measured, any negative features are invisible. This is the reason why LIMAB uses a distance measuring technique to ensure the true profile is always measured. Products as large as 2000 mm can be measured to a very high accuracy.

Patented technology

LIMAB have developed an algorithm that eliminates measuring errors due to the movement of the product in the measuring field ensuring reliable measurement irrespective of the material presentation.

3D user display

Due to the fast sampling of all lasers simultaneously the TubeProfiler is able to display the bar shape in 3D providing an interesting insight into various rolling mill problems that may have been missed with standard 2D graphs. For example, eccentric or damaged rolls in the mill stands can easily be detected.

Software

The software is designed for client/server mode with the possibility of several clients connecting to one server. The client software calculates and displays the shape of the measured product as a 2D cross-section or 3D graphical view. Trend graphs show key dimensions over the length of the bar. Numerical values display key dimensions and bar temperature. All measured values are logged to a database for archiving and post-production analysis.

Complete package

LIMAB provide a complete turn-key solution, one contractor takes full responsibility. The TubeProfiler includes all hardware and software needed for any mill installation. LIMAB provide commissioning training and on-going product support and service.

Features

Benefits

Rugged construction Reliable use in any mill environment  for either hot or cold applications
True profile measurement The only real-time system available, unlike shadow technology no interpellation of assumed data points
Proven system No hassle installation performs accurate measurement immediately after installation
Portable The gauge can easily be lifted and moved to a new measuring location without the need to reconfigure or calibrate.
High powered air cooling/cleaning Virtually maintenance free with minimal running costs
Motorised auto lifting table The gauge will automatically adjust to different pass-line heights when measuring different diameters no manual setting required
Constructed with standard ProfiCura 2D sensors Spare parts are readily available at low cost, ensuring very low on-going costs and no high-value spares inventory
Turn-key solution One contractor takes full responsibility for installation
Instant feedback Improve mill yield by giving instant  feedback on bar size allowing on target rolling very shortly after roll changes

Tube size range round or square 20-1600 mm
Resolution 0.01 mm up to 500 mm (0. 1mm above 500 mm)
Sensor measurement rate from 240 Hz
Repeatability for averaged numerical values ± 0.1 mm at 2σ
Number of lasers (min & max) 8-24
Laser measurement rate 2000 (Hz)
Lifting table travel (typical) ± 50 mm
Cooling air 2000 (m³/h)
Cooling air temperature 10-30 (°C)
Inner diameter 550 mm (depending on model)
Overall dimensions, from 2000 (h) x 1700 (w) x  600 (l)
Electrical power requirements 230 VAC, 50Hz, 16A or 120VAC, 60 Hz)