Measure online the diameter of a redrawed wire

[gustavosilvano]

Hello there!

My name is Gustavo and I work as an industrial engineer here in Brazil. I work at a steel mill, more specifically at the drawing area. Here we produce steel wires that will be annealed. The drawing system that we use consists of rolls and cassettes. But we're noticing a deviation from the nominal diameter, which is 1,25mm. I want to guarantee that the diameter as near as possible to 1,25mm. For that, I want to measure the diameter online, during the production. If I measure a deviation greater than 10um, it should stop the machine so that the operator can adjust the cassettes.
To measure, I want to use a contact sensor, because they are precise and cheaper than a laser sensor. Attached we have a schematic of how it would be. We'll use two sensors to get only the variation of diameter measure, filtering any vibration of the wire due to the process.

Here we have a catalog of this sensor (it's in portuguese):

https://www.keyence.com.br/mykeyence/?ptn=001

Is there any advice related to this project? Is there another type of sensor that cheap and reliable? I already know about the laser sensor, but it's not as precise as this contact sensor and is way more expansive.

Best regards.

Gustavo

 

[EdStainless]

Are you sure that you are measuring the critical diameter? Make sure that you measure in the most sensitive direction.
The laser micrometers that we used were far more sensitive and not much more expensive.
You don't need multi-axis general purpose ones, just the simple models and you are working over a very tight size range.
We always had issues with contact sensors.
Vibration, contamination of the contacts, temperature change, and simple plant damage.
Optical (laser of not) would be my only choice for this application.


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P.E. Metallurgy, Plymouth Tube

 

[IRstuff]

as near as possible

THAT is not a numerical specification; what accuracy do you actually require?

I think a bigger issue is WHY there is variation, and WHY does operator dinking around with cassette make a drastic difference? What does the cassette actually do?

TTFN (ta ta for now)
I can do absolutely anything. I'm an expert!

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[MagBen]

A deviation of 10 microns means a tolerance +/- 5 microns (+/-0.0002'') for 1.25 mm wire! Is your draw machine really capable for such a tight tolerance?!