TOSGAGE Series X-ray Thickness Gage General The X-ray thickness gage is used to measure the thickness of a strip continuously without contacting that strip. This gage uses the fact that the amount of radiation that passes through the strip varies with the thickness of that strip. The TOSGAGE-7525 is a high quality thickness gage for cold rolling achieving outstanding safety, operability, accuracy and cost-performance developed over many years. It has the following features. • Noise immunity is improved by digitizing the signals between the measuring head and the equipment cabinet. TOSGAGE -7525 • The operation-PC uses Windows® NT, and is a user-friendly PC. • A newly-developed X-ray generator is used, providing extremely accurate measurement results with a quick response time. The TOSGAGE-7525 focuses X-ray beams finely in the strip width direction to improve thickness resolution in the strip width direction, and making it suited to measuring the shape of the section of measured materials. The TOSGAGE-7525 can also be used as a AGC backup for when the fixed thickness gage (TOSGAGE-7521/7522) has failed. Configuration X-ray/shutter * Driving control box * Equipment cabinet Customer's distribution panel *〈AVR〉 warning lamp ⑤CVVS 3C 5.5S(AC200V) ③CVVS 2C 3.5S(AC200V) ①CV 3C 3.5S(AC200V,1φ) ⑳CVVS 8C 1.25S 35 NC-HIV 8S ⑥CVVS 3C 8S(AC100V) ④CVVS 2C 3.5S(AC100V) ⑪ Special cable (power) * Measuring head ⑦CVVS 20C 1.25S(Signal) ⑫ Special cable (Signal) ⑬ Special cable (Signal) (Customer's ⑧CVVS 10P 1.25S(Signal) D-type ⑭ Special cable (Snet) computer) ⑮ Special cable (motor power supply) ⑨CVVS 10P 1.25S(Signal) CVVS 4P 1.25S(Signal) 22 PG M B ⑯ Special cable (PG signal) 23 CVVS 20C 1.25S(Signal) ⑩5C-2V-CCY ⑰ CVVS 2C 2S (reverse limit) 29 CVVS 10P 1.25S AUI AUI 26 27 24 ⑱ CVVS 2C 2S (forward (PG Signal) AUI Transceiver Bridge ⑲ CVVS 2C 2S (standby) 34 Transceiver * Limit switch 30 CVVS 25 Transceiver 21 NC-HIV 8S AUI NC-HIV 8S 2C 2S (line center) 10BASE5 Conditions 28 1. Apart from special cables ⑪ to ⑮, all cables are (Operation-PC) the responsibility of the customer. C-type D-type Printer 2. Length of cable between equipment cabinet and 33 NC-HIV 32 automatic voltage regulator is 10m max. 8S D-type 3. Distance between automatic voltage regulator and customer's distribution board is 10m max. 4. Length of cable between driving control box and 31 CV 3C 3.5S(AC100V,1φ) customer's distribution board is 100m max. ②CV 3C 5.5S(AC200V,1φ) 5. LAN and terminators are the responsibility of the customer. (Hub) bridging and LAN separation are the responsibility of the customer. 6. The application of flame-resistant cable (judgment and liability) is the responsibility of the customer. 7. Components marked * are standard configuration components. Figure 1 Configuration and Cable Connections No. EJD-069 1 1. Measuring head 1 Equipment cabinet 1 Operation-PC 1 Automatic voltage regulator 1 Driving control box (also used as a junction box) 1 Standard accessories 1 set Safety valve (1) Flow switch (1) Limit switches (4) Sample holder (1) Cable ducts (1 set) Special cable (20 m) (1 set) Hose (20 m) (1 set) Standard spare parts (1 set) Fuses/lamps 1 set 2. 17-type monitor Transceiver (with cables) X-ray/shutter warning lamps (for three lamps) Standard Configuration Optional Configuration Measuring head peripheral equipment Rails Rack and rack mounting plate Hanger Hanger rails Test samples X-ray/shutter warning lamps 1 set (red/green) Piping parts Air filter Strainer Reducing valve (for air) Reducing valve (for nitrogen) Nitrogen escape valve Nitrogen cylinder Air dryer Cooling water supply unit Oil mist separator Flow rate gage (for cooling water) Pressure switch (for air) Pressure switch (for nitrogen) Valve stand Interface (for PI/O interface with purchaser's PC) Indicator/recorder Wide angle indicator (110°) Recorder (hybrid-type) Cabinet (houses control panel, recorder, etc.) Cables Various types Hoses Various types Accessories Maintenance PC Operation-PC printer 3. Individual Unit Configuration Measuring head The C-Frame can be broadly divided into the Xray generator, standard changer, and detector. Each component is an individual unit and can be replaced easily. <Main components> C-Frame (standard: measuring air gap height 750mm, depth 2500mm) X-ray generator Generator control power supply Standard changer Detector (ionization chamber) Ionization chamber power supply C-Frame carriage drive unit (AC motor) Air purge nozzle Safety valve Flow switch DC power supply unit (+5V, +24V) Cable duct Air cooler Driving control box (also used as junction box) This is integrated with junction box of the past, so it features the necessary control display on the machine side. <Main components> Driving control box X-ray and shutter ON/OFF switch X-ray interlock C-Frame carriage drive unit Carriage forward/reverse/stop switch Shutter and carriage drive interlock Control location selection switch (local, remote) Equipment cabinet The FA control computer (V300) was developed for industrial measurement and control. It is a computer that features reliability and expandability (utilizes a VME bus). No. EJD-069 2 <Main components> Equipment cabinet FA computer (V300) DC power supply unit (+24V) Circuit breaker (100V AC single phase) Circuit breaker (200V AC single phase) Isolated amplifier (for deviation output) Operation-PC Uses FA computer to display different kinds of settings, self-diagnosis and deviation trends. Communications are carried out via the microcomputer and Ethernet, settings are carried out via a microcomputer, and status detection information is sent and received. <Main components> FA3100 main unit (Windows® NT) 15-type color monitor Keyboard Mouse Ethernet board Standard software package Automatic voltage regulator This is used to stabilize the power supply provided to the main unit of the thickness gage. Specify frequency of either 50 Hz or 60 Hz. Input 200/220V AC ± 10%, 1φ (100/110V AC is also possible) Output 200V AC (0.8KVA), 1φ 100V AC (0.7KVA), 1φ Distortion 5% max., capacity 1.6kVA Measuring head peripheral equipment X-ray/shutter warning lamp Limit switches Documents Contract Specifications 5 copies Contract Drawings 5 copies Test Report 5 copies Operation Manual (including maintenance) 5 copies Schematic Diagram 5 copies Operating Principle When the X-rays emitted from the X-ray generator pass through the material being measured, they are scattered and absorbed by that material. The X-rays that pass through the material are received by the detector (ionization chamber) and are converted into electrical signals (ionization current) proportional to the quantity of X-rays. These signals are subjected to A/D conversion at the integrated A/D converter before being sent to the microcomputer by the highspeed serial interface. At the equipment cabinet, these signals are calculated by the microcomputer and then output as thickness signals. Integrated A/D converter V Detector Special Cables Special cable between driving control box and measuring head (20m). Standard spare parts Fuses 0.5A, 3A, 5A Lamps 40W Deviation output Calibration curve Measured material Setting Standard changer Hoses Special hose between customer's piping and measuring head (20m). Cooling water hose (neoprene, 3/4B) Air purge hose (neoprene, 1/2B, 3/4B) Nitrogen hose (neoprene, 1/4B) Thickness gage T Calibration information X-ray generator Figure 2 Operating Principle Measurement Method The TOSGAGE-7525 is a single-beam thickness gage that uses previously calibrated standard plates to create and store a calibration curve throughout the entire measurement range. The signals detected for the X-rays that have passed through the measuring material during measurements are applied to the calibration curve to derive the thickness. No. EJD-069 3 As shown in the sample calibration curve shown below (Figure 3), the measurement range is divided into several individual measurement ranges. The calibration curve is expressed as a combination of the individual calibration curves in each measurement range. memory. During measurement, the detector output is read in and then the thickness is calculated from the stored calibration curve and output in the form of analog or digital signal. The microcomputer has a state-of-the-art 32-bit microprocessor for high-speed calculations. Specifications General Specifications Detector output Range 0 Range 1 Range 2 Range 3 Range 4 Range 5 Range N → Thickness Figure 3 Calibration Curve The X-ray generator, detector and other electrical circuits on the X-ray thickness gage are subject to drift as time passes, so the gage must be calibrated at periodical intervals. Two calibration methods are used for this purpose: Full calibration (in which all calibration curves in the entire measurement range are recreated) and Calibration (in which the calibration curve in only one measurement range is recreated). Full calibration requires about two minutes and calibration requires about five seconds. This combination of two calibration methods is a unique Toshiba innovation unlike the methods used by any other company. As the calibration curve is created by predetermined calibration points, Full calibration can be performed regardless of settings. Using these two calibration methods, it is possible to, for example, perform Full calibration two to three times daily to maintain the measurement accuracy in the measurement range, and perform calibration near the nominal thickness during the short period of time when no strip is present in the X-ray beam (such as during coil changing, etc.) to eliminate drift. This allows setup to be performed with great precision when the strip is present in the X-ray beam. When the calibration curve is created, standard plates are automatically inserted, the detector output is read in and the calibration data is calculated and stored in the microcomputer Measured materials: Mild steel strip Measurement range: 1.00 to 16.00mm (0.85 to 17.92mm pure steel equivalent) Range for setting compensation: ± 15.00% (based on pure steel) Setting accuracy: ± SQRT [(linearity)2 + (reproducibility)2 + (noise)2] This is the accuracy when a test sample for accuracy test is used offline. Measuring air gap height of 750mm and time constant of 30ms. Linearity: Max. ± 0.1% of set thickness (2σ) Reproducibility: Max. ± 0.05% of set thickness or ± 0.05µm, whichever is greater (2σ) Noise: Thickness(mm) Noise(%) 1 to 7.99 Max.±0.12% 8 to 13.99 Max.±0.20% 14 to 15.99 Max.±0.24% (1.65σ) Drift: Max. ± (0.2% of set thickness + 0.5µm)/8h Measuring head Changes in air density to max. cooling water temperature variations ± 3°C and max. temperature variations around measuring head ± 5°C are not included. Max. temperature variations around equipment cabinet/driving control box ± 5°C. Response time: Max. 30ms (response 63% when thickness of 2mm is changed in 100µm increments) Calculation period: 10ms Calibration time: For full calibration Max. 150s For calibration Max. 5s For setup Max. 20ms No. EJD-069 4 (Does not include writing time for settings, however) Warm-up time: 1 hour or less from cold start (Time taken for measuring to become possible after switching the power from OFF to ON) 0.5 hour or less from X-ray ON (Time taken for measuring to become possible after switching the X-ray from OFF to ON) Measuring air gap: X-ray beam center Depth 2500 For operation-PC 100V AC ± 10%, 50/60Hz, 1kVA single phase Cooling water: Pure water or tap water passed through a 40 mesh filter Pressure: 0.2 to 0.5Mpa Flowrate: 10litter/min Temperature: 25°C ± 10°C (however, change in water temperature in one day shall be ± 3° max.) Tap water or filtrated industrial water Pressure: 0.2 to 0.5Mpa Flowrate: 30litter/min Temperature: 25°C ± 10°C 250 750 Air: Pass line Edges of measured material: Measurement of X-rays received by detector (Edge) Measurement Method Plate edge measurement accuracy: Max. ± 1mm (Max. 100mm/s for carriage speed) Carriage drive system: Inverter speed control (Standard is 2-level selection: 30 and 100mm/s) Carriage position measuring accuracy (Reproducibility): Max. ± 1mm Allowable ambient temperature: Measuring head Designed to be suitable for strip temperature 1200°C. Equipment cabinet/driving control box 0 to 40°C (no condensation) Operation-PC 5 to 35°C (no condensation) Power: For main unit (instrument) 200V AC ± 10%, 50/60Hz, 2kVA single phase (100V AC can also be supported by an optional transformer) For motorized carriage 200V AC ± 10%, 50/60Hz, 1kVA single phase Purified air containing no oil mist, that has been passed through a 10µm filter Pressure: Approximately 0.6 to 0.7Mpa 3 Flowrate: 1.5m [normal]/min Temperature: 25°C ± 10°C Nitrogen gas: Pressure: Approximately 0.02Mpa Purity: 99.99% min. Cables: Total length from measuring head to driving control box to equipment cabinet is 150m max. Ground: Less than 10Ω for circuit Less than 100Ω for safety Radiation leakage: Max. 2.5µSV/h at surface of X-ray generator cover with shutter closed Color: Toshiba standard paint color Measuring head Heat-resistant paint (gray) Equipment cabinet Munsell 5Y7/1 Operation-PC Manufacturer's standard color Automatic voltage regulator Munsell 5Y7/1 Driving control box Munsell 5Y7/1 Indicator frame Munsell N1.5 Recorder frame Manufacturer's standard color Others Manufacturer's standard color No. EJD-069 5 Functional Specifications Item Standard Specifications Special Order Specifications Setting location (Thickness setting, compensation setting, calibration, setup instruction, etc.) Operation-PC Purchaser's computer Equipment cabinet (maintenancePC) 7 digits △△△. △△△△mm 6 to 9 digits △△△. △△△ to △△△. △△△△△mm Code compensation Setting range 0 to 999 Settings Thickness setting Compensation setting 4 digits with ± sign ±△△. △△ (%) Remarks Up to 9 digits can be set △△△. △△△△△△mm Code compensation consists of one of the following two types: (code) (compensation 1) (compensation 2) Material code Steel type code Offgage setting Strip width 20 +15% -15% 500 0% 0% 980 -15% +15% Select either one of material code or steel type code 2 digits △△ 2 digits △△ 3 bands 5 bands µm setting (△△△△ µm) % setting (△. △△%) % setting (△. △△%) Max. 5 digits △△△△. △△mm Max. 16 digits (letters and numbers) None None Max. 6 digits (△△△△△△kg) Max. 6 digits (△△△△△. △m) No compensation (pass angle 0°) 1 type; angle fixed Preset value None Up to 16 passes Calibration/Setup instruction External (operation-PC) External (purchaser's computer) Full calibration Full calibration Calibration (Setup + range calibration) Calibration Setup Setup Equipment cabinet (maintenance-PC) Deviation range selection None 2-step changing by purchaser's computer Automatic changing (according to thickness setting) Deviation range value Set to any value on operation-PC Set to any value on purchaser's computer Time constant selection 0.01 second Automatic changing (according to thickness setting) Time constant value Set to any value on operation-PC Set to any value on purchaser's computer % deviation range selection None 2-step changing by purchaser's computer Automatic changing (according to thickness setting) % deviation range value None Set to any value on operation-PC Set to any value on purchaser's computer Coil no. Coil weight Coil length Pass angle compensation No. EJD-069 6 1µm unit 1ms unit 1% unit Output Specifications 1. Standard Specifications Item Standard Specifications Special Order Specifications Analog deviation output (µm or %) For control 1 insulated output (AGC/purchaser's computer, etc.) 4 to 20 mA/maximum deviation range Gage healthy (HEL) output AND conditions shown below: X-ray ON Shutter open Not test mode Not initial mode Automatic mode Open collector output Self-diagnostics Displayed on operation-PC 2. Remarks For control ± 10V/ max. deviation range For indicator/for recorder ± 10V/ each deviation range AND conditions for standard specifications and user specifications Printer output from operation-PC Optional Specifications PI/O input and output in addition to the standard specifications listed above is possible by installing an interface with an optional configuration. Item Standard Specifications Special Order Specifications Settings Thickness Compensation Strip width Self-diagnostics BCD 1 system Open collector Maximum load 24V DC, 50mA (1) Status output * Abnormal * Warning Open collector Maximum load 24V DC, 50mA Digital deviation output None Digital absolute output None BCD 1 system No-voltage relay contact Maximum load 48V DC, 0.1A (1) Code output BCD 3 digits (2) Status output * Unmeasurable * Full calibration request Both (1) and (2) open colletor or no-voltage relay contact 14-bit binary output with +/- sign ± 16000 maximum deviation range Open collector output Maximum load 24V DC, 50mA Max. 6 digits △△. △△△△mm Open collector output Maximum load 24V DC, 50mA Remarks Output period 0.01 second Output period 1 second Can be changed in 0.01 second increments No. EJD-069 7 Profile Measurement Specifications 1. Measurement Mode Item Scanning Pattern Full-width profile scanning Standard Specifications In this mode the carriage is made to scan in a strip width direction by a start profile measurement command, thereby measuring the whole width profile. The speed of the carriage is 30mm/s on both edges, and 100mm/s at the center. ←ライン流れ方向 Line flow direction WS DS Edge profile scanning In this mode the carriage is made to scan in a strip width direction by a start profile measurement command, thereby measuring the edge profile. WS (or DS) edge distance is set beforehand from the customer's computer. Edgeエッジ距離 distance WS DS Center measurement This mode measures the center of the strip continuously in a longitudinal direction. It is used as backup for AGC thickness gages (center measurement). WS DS 2. Data Processing The profile data processing shown below is carried out, and it is displayed on the operation-PC. Line center he’ hi’ hj’ hc hj’’ hi’’ i’ he’’ i’’ j’ WS j’’ Note: a. Edge distance settings i', i'', and j', j'' are the same. b. i can be set from 5 to 50mm (i can be set at 5 locations) c. j can be set from 50 to 100mm (edge drop standard) d. i < j (in these specifications the initial settings are i = 25mm, j = 75mm.) DS Figure 4 Section in Strip Width Direction 1) Crown Value Crown value, WS crown value, DS crown value are calculated from the measurements of center plate thickness, WS side specified measurement points and DS side specified measurement points. Crown values are calculated as follows: a) Crown value: chi = hc- (hi' + hi'')/2 b) WS crown value: chi' = hc-hi' c) DS crown value: chi' = hc-hi'' 2) Wedge Value Wedge value is calculated from the measured thickness at WS side specified measurement points and DS side specified measurement points. The formula for calculation is shown below. Whi = hi'' – hi' No. EJD-069 8 3) Edge Drop Amount Edge drop amount is calculated from the measured width between two points specified on the WS side and DS side. Calculations are made as follows. a) WS edge drop amount: eh' = hj' – hi' b) DS edge drop amount: eh'' = hj'' – hi'' Example of Display on Operation-PC Screen Figure 5 Thickness Deviation Trend Screen Figure 6 Thickness Deviation Profile Screen No. EJD-069 9 External Dimensions Guide roller X-ray beam center Detector Maintenance cover Maintenance cover Balance center of gravity Cable duct Air nozzle Drive unit Pinion module for driving: 5 P.C.D: 130 Note: 1. 2. 3. 4. Striker (for limit switch) (can be mounted on either left or right side) Position detection Maintenance mechanism cover Figure 8 X-ray generator Total weight of measuring head: Approximately 2000kg Scanning speed of measuring head: 1.8 to 18m/min Paint color of measuring head: See specifications For dimensions of H in the diagram see specifications. Figure 7 4-φ16 hole (mounting hole) Standard changer External Dimensions of Measuring Head (unit: mm) Cable lead-in hole Weight: approximately 250kg Cable lead-in hole External Dimensions of Equipment Cabinet (unit: mm) No. EJD-069 10 Figure 9 External Dimensions of Operation-PC (unit: mm) PF3/4 cable lead-in hole 4-φ6 mounting hole Glass cover φ φ Guard 2- 20 Cable lead-in hole 4- 10 hole (mounting hole) Figure 10 External Dimensions of Automatic Voltage Regulator (unit: mm) Applicable lamp 110V AC, 40W Figure 12 External Dimensions of Warning Lamp (unit: mm) Model – R-19 Applicable fluid – Water Material – Gun metal Pressure resistance – 1.5MPa Pressure setting – 0.25MPa Discharge side (PT1/2) Top view (from A to A above) (door opening/closing) Weight: approximately 70kg Figure 11 Approximately 100° Pressurizing side (PT1/2) External Dimensions of Driving Control Box (unit: mm) Figure 13 External Dimensions of Safety Valve (Unit: mm) No. EJD-069 11 22 hole Operating Movement after Operating angle operation angle Movement after operation Conduit plug Guard ring (mounted after purchase) 4-φ5.2 mounting hole rear M6 x 1 depth 14 3 Pipe connection PT3/4 or PT1 Circuit diagram P. no. Model no. Connection port dia. Switch 001 FS5-J-3/4 PT3/4 002 FS5-J-1 PT1 SPDT (1) microswitch 2 circuit double breaking Figure 15 Max. operating pressure: 1.03MPa Max. operating temperature: 120°C Material of parts contacting fluids: Chrome yellow, carbon, ethylenepropylene rubber Fluid: Water (acid, alkaline or oils cannot be used) Weight: 1.7kg Color: Black wrinkle finish Figure 14 External Dimensions of Limit Switch (unit: mm) External Dimensions of Flow Switch (unit: mm) Cooling water (Tap water) Pressure: 0.2 to 0.5MPa Flow rate: Approximately 10litter/min Temperature: 25 ± 10°C *1 *2 *3 Backwater Back pressure: max. 0.05MPa Screen mesh: 40 NO. Name Open: 0.25MPa 1/2" hose Closed: 0.22MPa Pressure setting: 0.4MPa Strainer 2 3 Single entry safety valve Air reducing valve 4 Air filter 5 Flow switch Detector 6 Mist separator Standard changer 7 Air dryer Detector 8 Solenoid valve X-ray generator 1/2" hose Open: 10l/min Closed: 6l/min 1/4" hose Pressure setting 0.02MPa Cooling water (Tap water or filtered industrial water) Pressure: 0.2 to 0.5MPa Flow rate: Approximately 10litter/min Temperature: 25 ± 10°C 1 3/4" hose Screen mesh: 40 3/4" hose Top frame Spray pipe Rail surface purge Rack surface purge Terminal box Purge air (dehumidified air) Pressure: 0.4 to 0.7 MPa Flowrate: 1m3[normal]/min Note: 1/2" hose Waste water (discharged outside) 9 Strainer 10 Air reducing valve 11 Pressure escape valve Nitrogen reducing valve Nitrogen cylinder 12 13 Remarks Supplied by customer Detector lower surface purge Degree of filtration : 5µm 3/8" hose Standard changer upper surface purge 1. in figure indicates JIS 0.98MPa ball valve. 2. Scope of supply for piping parts depends on specifications. 3. If there are large fluctuations in supply water pressure and pulsing, or if continuous operation of the safety valve causes problems with the amount of water discharge, a water pressure reducing valve* must be installed. In such cases, we recommend installing the pressure gages shown in *２ and *３. Figure 16 Piping Connections No. EJD-069 12 Other Related Models In addition to the TOSGAGE-7525, the following models are also available for use on steel lines. For details, please contact a Toshiba sales representative. TOSGAGE-7511 For general cold rolling TOSGAGE-7521/7522 For general hot rolling TOSGAGE-7524 For installation between hot rolling stands No. EJD-069 13 Notes on using the system: Because improper use of X-rays can be harmful to the human body, use of X-ray emitting technology is subject to the radiation-hazard safety regulations of your state. Please abide by those regulations when using the TOSGAGE-7525. Misuse of this product can result in property damage or human injury. Read related manuals carefully before using this product. Printed in Japan 2001-5 (TDOC) TOSHIBA Corporation 2001 All Rights Reserved. • Windows NT is a registered trademark of Microsoft Corporation, in the United States and other countries. • The information in this brochure is subject to change without notice. No. EJD-069 14