Online Quality Measurement

for Coil Edge Trimming and

Slitting Lines
Heimo Kernen
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 caseor 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 hardif not
impossibleto 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 poorquality 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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10

SQM 1200F Online Burr Height and Strip Width

Measurement System

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FocalSpec SQM1200F Burr Height and Strip Width Measurement System

Cabinet
Burr heigt

Pulse
encoder

Ethernet /
mill network

System components:

Scanning LCI-imager

Traversing system

Rotation pulse encoder

Electronics cabinet

User interface PC

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Burr height measurement for every second strip edge

(burr toward the measurement system)
Accuracy better than 1,5 m
(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 m

Burr height

Measurements

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Specifications
Scanning length (line width )
LCI imager height adjustment range
Automatic height positioning for keeping the measurement
distance within +- 1 mm to the surface
Stand off distance of the measurement head

max 1600 mm
50 mm, resolution 100 um ( SW controlled)

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

Pixel resolution
Height measurement accuracy for each pixel
Scanning time
Width measurement accuracy

6,7 mm, 1200 pixels

5,6 um x 50 um
standard deviation better than 1,5 um
< 60 s
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
Mill network

Ethernet
Ethernet

System components:

Cabinet
Camera
link

Edge sensors

Sensor positioning system

Rotation pulse encoder

User interface PC

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
defects

Rotary shear knife profile

Knife edge defect map (based on knife marks)

Defect positions in knife
Defect classification (size, depth, severity)
Knife wobble

mm

Knife edge defect map

1000 mm

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Specifications

Sensor distance to edge

Edge distance measurement range
The length of the measured 3D profile
The width of the measured 3D profile
Number of pixel in the measured 3D profile
Distance measurement resolution for each pixel (1 )

30 mm
4 mm
11,2 mm
50 m
2048
1,5 m

Minimum detected knife edge defect area

Minimum detected edge depth

1 mm x 1 mm
20 m

Maximum line speed

Measurement speed
Exposure time

300m / min ( = 5 m/s)

330 profiles / s
50 300 s

4 mm

11,2 mm

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Measurement speed calculations

Rotary knife diameter

Line speed

Maximum line speed

Diameter of the rotary knife:
Rotation speed
Measurements / 1 round
Time to record whole rotary knife (1000 mm)
Rounds needed for full profile data

300 m/min ( = 5 m/s)

320 mm (circle length = 1000 mm )
5 rounds/s
66
3 s ( 1mm between successive measurements)
15 rounds

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Edge sensor positioning system

Position control
Max
50 mm
Max 1000 mm

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

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

Burr height measurement

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Edge profile measurement

Burnish
depth

Sheet
thickness
m

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