Steel giant adopts NextSense 3D laser-optical hot-surface inspection method

IMAGE: Hot train rails are inspected by a laser-sectioning and optical system from NextSense. (Image credit: NextSense)

Graz, Austria--A major Turkish steel producer is optimizing the production of high-speed-compatible train rails with a photonics surface inspection method from NextSense based on laser light section technology to facilitate the non-contact examination of surfaces that are still hot, allowing defects in the surface structure to be detected in real time during the production process. Typically, by the time the product is accessible to visual inspection, many more pieces with the same defect might have been produced. The NextSense method eliminates this problem.

The new DIRIS 3D HOT method is based on laser light section technology, a method of optical 3D measurement technology that allows for the calculation of a precise height profile. To take the measurement, a laser line is projected on a mobile object. Shifts of the laser line caused by changes in the surface structure are registered by several cameras and converted by means of photometric calculations in 3D coordinates. Once the object has been completely guided along under the laser line, you get a complete height profile of the object.

Christoph Böhm, marketing manager of NextSense, explains, "Our DIRIS 3D HOT method works on a completely non-contact and automated basis. The customer gets 3-D data in real time, including the spatial depth of production errors as well as a complete documentation." Hence the method can be applied to surfaces that are still hot, such as those you have in steel production immediately after rolling.

Automation of the surface inspection process also improves work safety when dealing with hot steel products of more than 1,000 degrees Celsius, because cameras withstand the heat, not employees. Naturally, another great advantage is the complete documentation of the measurement results: objective 3-D data in color diagrams replace subjective assessments made by employees.

Upon exhaustive examination of the method, a leading steel producer in Turkey decided to order a SURFILES DIRIS 3D HOT facility for the production of faultless rails. Especially when it comes to train rails, the quality requirements have been rising enormously due to the fact that more high-speed lines are being upgraded. The deal that has now been struck adds a success benchmark for the newly established "Surface Inspection & Profile Measurement Systems" (short: SURFILES) division of NextSense. Alongside the rapidly growing segment of portable profile measurement devices, "CALIPRI", this multi-million contract has contributed decisively to the fact that the company has exceeded its mid-term company goal, namely the double-digit million turnover limit.

SOURCE: NextSense; http://www.nextsense.at/en/company/news/items/3D-Oberflaecheninspektion_ueberzeugt_Stahlriesen.php