Laser Based width Gauge System Software (LWG)

Objective:

In the steel industry, accurately measuring slab width during production is critical. Traditional contact methods fail due to high temperatures and motion. To address this, an automated gauge system was developed using precision-mounted lasers to measure slab width in real-time as it moves from the furnace to the roughing mill.

Solution:

The system integrates laser sensors with a server-client architecture. The server processes real-time laser data, while the client displays measurements to plant operators. The key functions include:

• Setting up the roughing mill with precise slab width data.
• Detecting and rejecting slabs with incorrect widths before rolling, conserving energy.
• Enabling statistical analysis and control of the width spread/squeeze process.

Simulation Approach:

Given the hazards and costs of testing in an industrial environment, a multi-level simulation framework was implemented. The software allows switching between real and simulated data sources at runtime, facilitating proof of concept, development, validation, and troubleshooting. Individual modules, such as laser readings and sensor data, could be tested independently before full system deployment.

Impact:

This solution improved operational efficiency, reduced waste, and enhanced quality control by ensuring only slabs with correct dimensions proceed through the process.

Clients: International Steel Manufacturer for Industrial Automation 

Technology Used