DEVICE FOR DETECTION OF DEFECTS IN STRIPS

Abstract

A stoning or honing device for automatically applying an essentially constant and uniform pressure of an abrasive hard component onto a suspended portion of a continuously moving metal strip surface, for the purpose of defect visual inspection, includes: a main frame supporting at least one carriage bearing a hard component, the carriage being connected to a drive system for moving the hard component towards the metal strip and to apply a controlled contact pressure thereof on the metal strip surface; and a means for moving transversally and back and forth at a defined speed the hard component bearing carriage with respect to a continuous motion direction of the strip. The device includes, on each strip side, a plurality of hard component bearing carriages having each a defined width stroke and arranged according to at least three different locations respectively associated with three separate rails including drive and control systems.

Claims

1: A stoning or honing device for automatically applying an essentially constant and uniform pressure of an abrasive hard component onto a suspended portion of a continuously moving metal strip surface, the purpose of defect visual inspection, comprising: a main frame supporting at least one carriage bearing a hard component, the carriage being connected to a drive system configured to move the hard component towards the metal strip and to apply a controlled contact pressure thereof on the metal strip surface; and a means for moving transversally and back and forth at a defined speed the hard component bearing carriage with respect to a continuous motion direction of the strip; wherein the device comprises, on each strip side, a plurality of hard component bearing carriages having each a defined width stroke and arranged according to at least three different locations respectively associated with three separate rails including drive and control systems per side, with respect to a travel direction and/or the transverse direction of the strip, and that are arranged according to a repetitive arrangement of elements, line by line, and wherein a line is shifted by a half of an element about a preceding or following line, so that each hard component bearing carriage located on one side of the strip has a corresponding carriage disposed opposite on the other side of the strip, wherein the hard components of the carriages disposed opposite face each other while both carriages are moved synchronously, so as to avoid any strip deflection when pressure is applied.

2: The stoning device of claim 1, wherein the hard component comprises at least two parts of stone, ceramic, abrasive polymer, or emery paper.

3: The stoning device of claim 1, comprising from 2 to 5 hard components.

4: The stoning device of claim 1, wherein the carriage bearing a hard component is coupled to the drive system with a pivoting part allowing self-adjustment of the hard surface to the strip, preferably a ball joint, a spring suspension system, or flexible rubber.

5: The stoning device of claim 1, wherein the drive system configured to move the hard component towards the metal strip surface and away thereof and to apply a controlled contact pressure on the strip surface comprises a screw jack, a hydraulic cylinder, a gas cylinder, or a rack and pinion gear assembly.

6: The stoning device of claim 1, wherein the carriage is provided with a position or edge sensor.

7: The stoning device of claim 1, wherein the stoning device is computer- or PLC-controlled.

8: The stoning device according to claim 1, wherein the stoning device has a size less than 2 meters in a strip travel direction, preferably less than 1 meter.

9: The stoning device according to claim 1, further comprising a main frame having a C or O shape having at least one main beam on each side of the strip to support the carriages with their hard components and drive systems.

10: The stoning device of claim 9, wherein at least one beam of the C-shaped or O-shaped main frame is arranged to be translated or rotated out of a strip pathline in a standby location of the device.

11: The stoning device of claim 10, wherein, in case of C-shaped main frame, the beams are configured to be vertically rotated to achieve a V-opening.

12: The stoning device according to claim 1, wherein the stoning device is configured to be arranged to stone a portion of metal strip in vertical run, in horizontal run, or in oblique run.

13: The stoning device according to claim 1, wherein the means for moving transversally and back and forth at a defined speed the hard component bearing carriages with respect to the continuous motion direction of the strip comprises screw balls or sliding rails.

14: The stoning device according to claim 1, wherein the means for moving transversally and back and forth at a defined speed the hard component bearing carriage with respect to the continuous motion direction of the strip is arranged so as to permit each carriage to be driven separately, preferably by using a belt, a tooth belt, a cable, or a rack.

15: A method for stoning or honing a metal strip surface continuously moving at low speed, for the purpose of defect visual inspection, using the device according to claim 1, comprising the steps of: decreasing a strip moving speed from a standard speed to a value comprised between 1 and 20 meters per minute and preferably between 10 and 15 meters per minute; moving the main frame supporting the carriages from a standby position to a starting working position; for each carriage, moving the hard components downwards to bring them into contact with the strip using the respective drive systems; performing the stoning work by controllably moving the carriages transversally with respect to the strip movement, until a desired stoned portion of strip is obtained; for each carriage, moving the hard components upwards to pull the hard component away from the strip using the respective drive systems; moving the main frame supporting the carriages from the working position to the standby position; possibly performing in a standby position an automatic cleaning operation by wiping the hard components with a brush or unwoven material; and increasing again the strip moving speed to standard speed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The present invention will be described in even greater detail below based on the exemplary figures. The invention is not limited to the exemplary embodiments. Other features and advantages of various embodiments of the present invention will become apparent by reading the following detailed description with reference to the attached drawings which illustrate the following:

[0029] FIG. 1, already mentioned, represents an unprocessed surface presenting depressions and bumps.

[0030] FIG. 2, already mentioned, shows the surface of FIG. 1 modified by the stone wiping effect.

[0031] FIG. 3 is a top view of the 3-stone system embodiment according to the invention.

[0032] FIG. 4 is a side elevation view of the stone assembly with carriage and drive.

[0033] FIG. 5 is a cross-sectional view of a preferred embodiment for a 2-side stoning system according to the invention with main frame and global drive system.

DETAILED DESCRIPTION

[0034] The present invention relates to a mechanical device or installation for stoning that can be easily implemented in the inspection section of continuous processing line for a strip and especially a steel strip. The invention also relates to a stoning procedure on both strip sides, both under control and in reproducible manner, in less than 2 minutes, preferably in less than 1 minute, for a total wiped surface being at least between 1 and 5 m.sup.2 per side. The invention can however be used on only one side if required.

[0035] Stoning or honing consists here in sliding a hard material on a softer surface to enlighten some of the pre-existing defects of the surface by changing the light reflection thereof after the hard material has wiped the surface with defined pressure.

[0036] More specifically, a first aspect of the present invention relates to a stoning or honing device for automatically applying an essentially constant and uniform pressure of an abrasive hard component onto a suspended portion of a continuously moving metal strip surface, for the purpose of defect visual inspection, comprising:

[0037] a main frame supporting at least one carriage bearing a hard component, said carriage being connected to a drive system for moving the hard component towards the metal strip and for applying a controlled contact pressure thereof on the metal strip surface;

[0038] a means for moving transversally and back and forth at a defined speed the hard component bearing carriage with respect to the continuous motion direction of the strip;

said main frame further comprising on each strip side, a plurality of hard component bearing carriage having each a defined width stroke and arranged at different locations with respect to the travel direction and/or the transverse direction of the strip,
wherein each hard component bearing carriage located on one side of the strip has a corresponding carriage disposed opposite on the other side of the strip,
characterised in that the hard components of said carriages disposed opposite face each other while both carriages are moved synchronously, so that to avoid any strip deflection when pressure is applied, and in that the hard component bearing carriages having each a defined width stroke are arranged according to at least three different locations respectively associated with three separate rails including drive and control system per side, with respect to the travel direction and/or the transverse direction of the strip and are arranged according to a repetitive arrangement of elements, line by line, wherein a line is shifted by the half of an element about the preceding or following line.

[0039] According to preferred embodiments, the device further comprises at least one of the following characteristics or a suitable combination thereof:

[0040] the hard component is made of at least two parts of stone, ceramic, abrasive polymer or emery paper;

[0041] the device comprises from 2 to 5 hard components per side of the strip; the carriage bearing a hard component is coupled to the drive system with a pivoting part allowing self-adjustment of the hard surface to the strip, preferably a ball joint, a spring suspension system or flexible rubber; the drive system for moving the hard component towards the metal strip surface and away thereof and for applying a controlled contact pressure on the strip surface is a screw jack, a hydraulic cylinder, a gas cylinder or a rack and pignon gear assembly;

[0042] the carriage is provided with a position or edge sensor;

[0043] the device is computer- or PLC-controlled;

[0044] the device has a size less than 2 meter in a strip travel direction, preferably less than 1 meter;

[0045] the device comprises a main frame having a C or 0 shape having at least one main beam on each side of the strip to support the carriages with their hard components and drive systems;

[0046] at least one beam of the C-shaped or 0-shaped main frame is arranged to be translated, rotated out of the strip pathline in a standby location of the device;

[0047] in case of C-shaped main frame, the beams are capable to be vertically rotated according to a V-opening;

[0048] the device can be arranged to stone a portion of metal strip in vertical run, in horizontal run or in oblique run;

[0049] the means for moving transversally and back and forth at a defined speed the hard component bearing carriages with respect to the continuous motion direction of the strip comprises screw balls or sliding rails;

[0050] the means for moving transversally and back and forth at a defined speed the hart component bearing carriage with respect to the continuous motion direction of the strip is arranged so as to permit each carriage to be driven separately, for example by using a belt, a tooth belt, a cable or a rack.

[0051] A second aspect of the present invention relates to a method for stoning or honing a metal strip surface continuously moving at low speed, for the purpose of defect visual inspection, using the device according to anyone of the preceding claims, comprising the steps of:

[0052] decreasing the strip moving speed from a standard speed to a value comprised between 1 and 20 meter per minute and preferably between 10 and 15 meter per minute; moving the main frame supporting the carriages from a standby position to a starting working position;

[0053] for each carriage, moving the hard components downwards to bring them into contact with the strip using the respective drive systems;

[0054] performing the stoning work by controllably moving the carriages transversally with respect to the strip movement, until a desired stoned portion of strip is obtained;

[0055] for each carriage, moving the hard components upwards to pull the hard component away of the strip using the respective drive systems;

[0056] moving the main frame supporting the carriages from the working position to the standby position;

[0057] possibly performing in standby position an automatic cleaning operation by wiping the hard components with a brush or unwoven material;

[0058] increasing again the strip moving speed to standard speed.

[0059] The device of the invention is less than 2 meters long and preferably less than 1 meter long, allowing an easy implementation in existing lines. It can be used on horizontal and vertical pass lines with a preference for vertical pass line.

[0060] The device is made of different parts as it will be explained in detail hereinafter, each part having a dedicated function in order to uniformly wipe a stone with a defined pressure across a strip moving slowly, typically between 1 and 20 meter per minute (mpm) but preferably, and in practice, between 10 and 15 mpm, to cover the total length of the strip to wipe according to the time made available by the exit looper and to the line speed of the processing section.

[0061] Stone assembly according to the invention is shown on FIG. 4. Stone 5, that can be chosen by the user according to the requirements, will be fixed on a steel or aluminium plate, the carriage 4 connected to the shaft of an air cylinder 2 by means of a rotating device 3. If required, more than a single stone may be fixed on the plate 4 to cover the desired surface.

[0062] The air cylinder 2 performs the raising function to allow the stone coming over the strip without touching the strip edges and the rotating self-adjustment device 3 has the function to ensure that the stone will touch the strip on all its surface even if both the strip and cylinder are not perfectly perpendicular, a frequent situation that may be in relation with the strip flatness at this location. This also allows to avoid that an uneven strip be scratched by the edges of the stone(s). The pressure between the stone and the strip is ensured by an adjustable air-controlled system. This allows to change the contact pressure in agreement with specific user requirement or specific product to stone (effect of steel grade, thickness, etc.).

[0063] The automatic cleaning operation performed by wiping the hard components with a brush or unwoven material can also be made just before or after the stoning operation.

[0064] According to FIG. 3 and FIG. 4, the device of the invention has a main frame to support the complete equipment, 1 to 5, and preferably 2 to 3 stones 5 per side, a system to move the stones transversally 12 with regard to the line axis of each stone 5, fixed on carriage 4. A system 2, for example an air cylinder, is implemented to move the stone and its plateau up and down as well as to control the applied pressure between the strip and the stone.

[0065] The top and bottom stones with reference to both strip sides will face each other while synchronously travelling to avoid any strip deflection when pressure is applied. In that respect the present invention provides an alternative solution of WO 2010/049596 in case stoning is effected on a suspended portion of strip. In the latter case a special means was provided in order to apply variable pressure of the stoning elements as a function of the longitudinal strip tension.

[0066] According to FIG. 3, the strip 6 is moving in the classical travel direction (see arrow) at a speed preferably between 10 and 15 mpm while the device of the invention may be used in a wider range, from 1 to 20 mpm. For example, the lower strip speed will be used when special surface examination must be performed. However, when such a low speed is used, it is not expected that the whole 5-meter long surface could be stoned owing to the currently available lines with classical processing strip speeds for steel sheet.

[0067] Main frame 1 supports the top and bottom stone assemblies with their travelling system. This main frame 1 can be either of O or C (see FIG. 5) shape. In the O shape, in addition to the supporting beams parallel to the strip and located in front of each face of the strip respectively, there is a perpendicular beam connecting said parallel beams on each lateral edge, while, in the C shape, this perpendicular beam is only present on one edge of the strip. One or more parts of the main frame 1 are possibly moving. For example, at least one of the beams of main frame 1 may rotate or move, either horizontally or vertically, to increase the distance to the strip and/or make maintenance easier.

[0068] The assembly of cylinder 2, rotating device 3, carriage 4 and stone 5 is connected to a sliding rail 12. The carriages 4 are individually moved by a mechanical system like an electrical motor, an air cylinder or similar 9. The drive system has the suitable equipment to identify the carriage position all along its transversal movement.

[0069] As the total strip surface has to be covered, more than one carriage assembly with rail and drive has to be used for each strip side or face. The exact number, typically between 2 and 4, has to be determined in view of fulfilling the requirement in available time for operation which includes low strip speed, extent of surface to stone and travelling stone speed. According to the invention, it is advantageous to drive each carriage separately but always with synchronization of corresponding top and bottom stone assemblies.

[0070] An example of the invention device shown in FIG. 5 is a device preferably dedicated to a galvanizing line processing for a 1850 mm-width strip with a maximum process speed of 180 mpm. The calculation has shown that a 3-stone assembly has to be installed on each strip side to make possible the stoning of 5 meters long at full (maximum) width in less than 1 minute while the strip is travelling in the device at a speed between 10 and 15 mpm. The stone assemblies can be advantageously arranged according to a repetitive arrangement of elements (see FIG. 3), line by line, wherein a line is shifted by the half of an element about the preceding or following line.

[0071] In this particular embodiment, three separate rails including drive and control system are used per side. The exact stroke of each stone will be adjusted according to the exact strip width to stone. For example, in this embodiment, the central stone assembly will have a stroke of 800 mm, while the two external stone assemblies will have each a stroke of 550 mm, with overlap between the aforementioned strokes.

[0072] Different types and sizes of stone can be used according to the invention. However, the stone size is typically between 10100 mm to 100200 mm. This is expected to be the best compromise between availability, weight, surface to cover and kinetic analysis of the equipment.

[0073] When the system is not used, the 3-stone assembly will advantageously be waiting on an end of the main frame, out of the strip pass line. This will allow, in safe condition for the operators, some cleaning and maintenance if required.

[0074] When applying the stoning procedure is desired, the line speed in this section will firstly and preferably be reduced to the target value of about 10-15 mpm. Then the stone carriages will be moved to their starting position in front of the strip. The stone are moved down to the strip on each strip side, and the contact pressure applied. The travelling movement of each carriage can now start. It is controlled by computer or similar, using a position sensor implemented in the drive system. After that the desired stoned length has been obtained, the stones are moved up, the line speed can be reincreased to the process speed as required. Finally, the stones move back to their standby location.

[0075] The stone assembly is made such that it can be easily replaced either during maintenance but also in operation. The main frame and further the whole system could possibly be designed in order to allow transversal move so that to put the whole system out of the line, for example by mounting the frame bearing the stoning equipment on guide rollers.

[0076] While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. It will be understood that changes and modifications may be made by those of ordinary skill within the scope of the following claims. In particular, the present invention covers further embodiments with any combination of features from different embodiments described above and below. Additionally, statements made herein characterizing the invention refer to an embodiment of the invention and not necessarily all embodiments.

[0077] The terms used in the claims should be construed to have the broadest reasonable interpretation consistent with the foregoing description. For example, the use of the article a or the in introducing an element should not be interpreted as being exclusive of a plurality of elements. Likewise, the recitation of or should be interpreted as being inclusive, such that the recitation of A or B is not exclusive of A and B, unless it is clear from the context or the foregoing description that only one of A and B is intended. Further, the recitation of at least one of A, B and C should be interpreted as one or more of a group of elements consisting of A, B and C, and should not be interpreted as requiring at least one of each of the listed elements A, B and C, regardless of whether A, B and C are related as categories or otherwise. Moreover, the recitation of A, B and/or C or at least one of A, B or C should be interpreted as including any singular entity from the listed elements, e.g., A, any subset from the listed elements, e.g., A and B, or the entire list of elements A, B and C.

REFERENCE SYMBOLS

[0078] 1 main frame [0079] 2 air cylinder [0080] 3 rotating device (ball joint) [0081] 4 carriage [0082] 5 stone [0083] 6 metal sheet [0084] 7 ball screw [0085] 8 edge sensor [0086] 9 motor [0087] 10 coupler [0088] 11 bearing [0089] 12 sliding rail [0090] 101 surface depression [0091] 102 surface bump [0092] 103 light rays