Online Quality Measurement

for Coil Edge Trimming and

Slitting Lines
Heimo Keränen
31. 8. 2012
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Edge trimming and slitting

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Typical edge cut parameters

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Knife edge conditions

If the line is straight between the nick (shiny)

of an edge and the break (dull area) and the
fracture is clean, it is a good edge.

If the line is uneven or the break is rough, it

is a bad edge, caused by improperly set
cutting knives.

(Source: Al Zelt: How to avoid slit –in coil slitting problems, Coil
Processing, March 2006)
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Controllable variables in slitting and trimming (*)

(*) Al Zelt: How to avoid slit –in coil slitting problems, Coil Processing, March 2006

Horizontal and lateral knife clearance

• Horizontal knife clearance is the most significant of these variables

• Typically set to 7 - 10 percent of the metal thickness

• The thinner the metal, the harder it is to achieve the correct clearance.

• Each metal has an optimal clearance, and even the same metal from a different
source or thickness might (and usually does) require a different clearance.

• Excessive vertical knife clearance, or overlap, may be the culprit in a multitude of

strip defects, including edge wave, crossbow, camber, and deep knife marks. It also
can damage tooling, such as the knife and stripper rings, and can even wear out
the slitter.

• There are no published formulas or equations that work in every case—or even in
most cases.

• Therefore, it is essential to look at the results, and then adjust as necessary.

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Controllable variables in slitting and trimming

Tooling

• If the tooling is in poor condition or not manufactured to the correct

specification and/or plastic shims are used, it is very hard—if not
impossible—to get accurate clearances between the knives.

• If spacers are damaged (nicks and dings), they will not seat properly.
This will cause inaccurate horizontal clearances.

• The knives might wobble, causing clearance variations, which will

result in an edge that is either of poor quality or of uneven quality

• Damaged tooling can cause the knives to clash, producing chips

and nicks on the knife's cutting edges
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Controllable variables in slitting and trimming

Machine

• If the machine has not been maintained, the bearings are loose, or the shoulders are damaged, edge
quality will get poor.

Burrs
• The primary cause of burr is a horizontal knife clearance that is too tight or too loose.
• An incorrect clearance automatically causes a poor quality edge. In fact, one of the characteristics of a poor-
quality edge is burr.
• If horizontal clearance is too loose, the metal gets stretched around the knife and tears.
• If horizontal clearance is too tight, a lot more force is required to cut the material
• The only way you can apply more force is to lower the knives, and this produces burr.
• A dull knife automatically creates burrs. The material wraps around the dull corner of the knife and tears.
Therefore, it is important to use the right knife for different slitting needs.
• A knife that dulls too quickly will cause burring.
• It is preferable to use the most wear-resistant knife possible so that the edge remains sharp for the longest
period of time.
• A vertical knife clearance that is set too deep (too much overlap) also causes burr.
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Controllable variables in slitting and trimming

Edge wave

• Although edge wave can be caused by stresses in the metal, most edge wave is "slit-in."
• Too much vertical clearance, or overlap, causes edge wave.
• Other contributing factors are poor stripper ring practice ( stripper ring ODs are too small )
• If the rings are too big, the metal will become stretched at the edges.
• If they are out of parallel, this also will contribute to edge wave.

Knife marks
• Knife marks on the strip almost always are caused by poor stripper ring practices.
• Proper stripper ring practices include utilizing male and female rings in different sizes and hardnesses.
• Size and hardness are not absolute constants and may vary from machine to machine. The size should
vary from one metal and thickness to another.
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FocalSpec Coil Edge Quality

Measurement Systems

• SQM 1200E Coil Edge Quality Measurement

System for Trimming Lines

• SQM 1200F Online Burr Height and Strip Width

Measurement System
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SQM 1200F Online Burr Height and Strip Width

Measurement System
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FocalSpec SQM1200F Burr Height and Strip Width Measurement System

Pulse Cabinet
encoder

Burr heigt
Ethernet /
mill network

System components:

• Scanning LCI-imager
• Traversing system
• Rotation pulse encoder
• Electronics cabinet
• User interface PC
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Measurements

Burr height
• Burr height measurement for every second strip edge
(burr toward the measurement system)

• Accuracy better than 1,5 µm

(Accuracy defined as the standard deviation
of the averaged burr height reading,
the average is calculated of 10 measurements)

• Width measurement of the strip

• Accuracy 40 µm
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Specifications
• Scanning length (line width ) max 1600 mm
• LCI imager height adjustment range 50 mm, resolution 100 um ( SW controlled)
• Automatic height positioning for keeping the measurement
distance within +- 1 mm to the surface
• Stand off distance of the measurement head 30 mm

• TCP/IP connection to machine PLC

• Set up widths for each slit
• Tolerance limits for burr height and widths
• Warning signals for slitted width out of tolerance
• Warning signals for burr height out of tolerance)

• Line length of the 3D profile measurement 6,7 mm, 1200 pixels

• Pixel resolution 5,6 um x 50 um
• Height measurement accuracy for each pixel standard deviation better than 1,5 um
• Scanning time < 60 s
• Width measurement accuracy better than +- 40 um
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FocalSpec SQM1200 E Coil Edge Quality

Measurement System for Trimming Lines
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FocalSpec SQM 1200E Coil Edge Quality Measurement System

Cabinet
Camera
link
Pulse encoder
Ethernet Mill network
Ethernet

System components:

• Edge sensors
• Sensor positioning system
• Rotation pulse encoder
Cabinet
• User interface PC
Camera
link • 24V power supply
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Measurements
Edge profile
• Average profile parameters
( averaging length as a parameter)
• Rollover depth
• Burnish depth
• Fracture depth
• Fracture angle
• Edge wave
• Error values vs. set value
Repeating edge
Rotary shear knife profile defects

• Knife edge defect map (based on knife marks) mm

• Defect positions in knife

• Defect classification (size, depth, severity)
• Knife wobble

Knife edge defect map 1000 mm

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Specifications
• Sensor distance to edge 30 mm 4 mm
• Edge distance measurement range 4 mm
• The length of the measured 3D profile 11,2 mm
• The width of the measured 3D profile 50 µm
• Number of pixel in the measured 3D profile 2048
11,2 mm
• Distance measurement resolution for each pixel (1 σ ) 1,5 µm

• Minimum detected knife edge defect area 1 mm x 1 mm

• Minimum detected edge depth 20 µm

• Maximum line speed 300m / min ( = 5 m/s)

• Measurement speed 330 profiles / s
• Exposure time 50 – 300 µs
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Measurement speed calculations

Rotary knife diameter

Line speed

• Maximum line speed 300 m/min ( = 5 m/s)

• Diameter of the rotary knife: 320 mm (circle length = 1000 mm )
• Rotation speed 5 rounds/s
• Measurements / 1 round 66
• Time to record whole rotary knife (1000 mm) 3 s ( 1mm between successive measurements)
• Rounds needed for full profile data 15 rounds
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Edge sensor positioning system

Position control
Max
50 mm
Max 1000 mm 3 * 400 VAC, 50 Hz

• Traverses sensor head according to edge trimming width

• Maximum travel 1000 mm
• Automated system calibration with a reference plate
• Positioning accuracy +- 0,1 mm
• Maximum angle error +- 0,1 degrees
• Maximum traversing speed 50 mm / s
• Inductive end position sensor , IFM, 24 VDC
• Servo motor control, supply voltage 3 * 400 VAC, 50 Hz
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Measurement technology

• FocalSpec LCI Technology

• A non-contact optical 3-D profiler based on patented lateral chromatic imaging

(LCI) technology
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Burr height measurement

Burr height
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Edge profile measurement

Burnish
depth

Sheet
thickness
µm
Fracture
depth
Fracture
angle
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Conclusions
• FocalSpec LCI imaging technology provides a new solution for steel edge quality and rotary knife
condition monitoring at slitting and edge trimming lines.

• Parameters obtained directly from a measured edge profile:

Edge parameters
• Edge burr height
• Burnish depth
• Fracture depth
• Fracture angle
• Sheet thickness
• Edge wave
Rotary knife condition
• Edge damages in knife surface (causing repeating defects in the edge of the coil)
• Wobble

• Integrated strip width measurement

• High resolution information can be used for controlling knife clearance, tooling and usage time.
 Thank You !!!

For more information:

FocalSpec Ltd
info@focalspec.com