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In-process detection of miniature size holes in cold-rolled steel strips

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Abstract

In the steelmaking industry, the demand and expectations from the customers are more stringent than ever, primarily owing to increased competition and stressed margins. Any steel coil with holes on the surface passed to the customer can potentially result in a severe complaint and a dent in the company’s reputation of being a quality product supplier. In the cold-rolling mills (CRM), supplier companies roll premium-grade steel strip products for several industry sectors including automobile customers. Manual and other pre-existing detection techniques of smaller miniature size holes on the strip moving with the high line speed is highly unreliable. Passing an undetected hole to the customer has serious consequences as it may cause damage to the costly equipment like die and can result in rejection of a complete BIW (body in white). To overcome this challenge, we propose an image processing-based miniature size hole detection system, which helps CRM (cold-rolling mill) to detect the material with pinholes in-process and prevents them from reaching the customers. Equipped with an innovative imaging setup including blue light and viewing angle enhancements, our proposed system surpasses the pre-existing hole detection technologies by a huge margin. This system has been developed and tested in a customer-facing line.

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Data Availability

All data generated or analyzed during this study are available within the article.

Abbreviations

CRM:

cold-rolling mill

HSM:

hot strip mill

CR:

cold-rolled

BIW:

body in white

mpm:

meters per minute

DAQ:

data acquisition

HDS:

hole detection system

CCD:

charge-coupled device

MSER:

maximally stable extremal region

RCL:

Recoiling Line

INR:

Indian Rupee

SNR:

signal-to-noise ratio

SVM:

support vector machine

CNN:

convolutional neural network

BW:

box-and-whiskers

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Acknowledgements

The authors would like to express their gratitude and thank the Automation Division of TATA Steel Ltd., Jamshedpur for giving them the opportunity and allowing them to use their state-of-the-art laboratory facilities to conduct this research.

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Authors and Affiliations

  1. School of Electronics Engineering, Vellore Institute of Technology, Vellore, India

    Dibyayan Patra

  2. Department of Computer Science and Engineering, Indian Institute of Information Technology Raichur, Karnataka, India

    Suresh Chavhan

  3. Automation Division, TATA Steel Ltd., Jamshedpur, India

    Chitresh Kundu

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  1. Dibyayan Patra
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  2. Suresh Chavhan
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  3. Chitresh Kundu
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Correspondence to Chitresh Kundu.

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Author contribution

Dibyayan Patra: conceptualization, investigation, methodology, prototyping, visualization, writing original draft of manuscript. Suresh Chavhan: supervised the investigation, methodology, validation, reviewing draft of manuscript, supervision. Chitresh Kundu: supervised the conceptualization, reviewing and editing, supervision.

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Patra, D., Chavhan, S. & Kundu, C. In-process detection of miniature size holes in cold-rolled steel strips. Int J Adv Manuf Technol 124, 633–645 (2023). https://doi.org/10.1007/s00170-022-10388-9

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  • DOI: https://doi.org/10.1007/s00170-022-10388-9

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