Mate Gauge has successfully shipped its largest MG5 laser thickness measurement system for a leading North American steel manufacturer, featuring a custom horizontal C-frame configuration. This three-year partnership highlights significant advancements in laser thickness measurement technology, demonstrating the system's ability to deliver precision and reliability in demanding steel manufacturing environments.
Industry Challenge
Steel manufacturing facilities require highly accurate and robust thickness measurement solutions across various production lines. The key demands included:
- Highly accurate inline measurements for galvanized steel
- Seamless integration with existing production systems
- Durability and performance in harsh industrial conditions
- Real-time data visualization, monitoring, and automated reporting
Technical Specifications for galvanized/galvannealed steel
Line-1 Requirements
- Material Width: 30" - 75" coils
- Thickness Range: 0.020" - 0.095"
- Measurement Accuracy: ±5 to 10 μm
- System Repeatability: Better than 5 μm
Line-2 Requirements
- Material Width: 24" - 60" coils
- Thickness Range: 0.009" - 0.050"
- Measurement Accuracy: ±5 to 10 μm
- System Repeatability: Better than 5 μm
MG5 Inline Thickness Gauge Solution
The MG5 system was chosen for its robust capabilities, including an 80-inch measuring stroke and 50mm PRO sensors.
Key system features include:
- Two-stage cooling system to prevent thermal drift
- Air Purge mechanism to keep sensors clear of debris
- Heavy-duty motorized belt drive actuator for reliability in a continuous production environment
- 15-inch Touchscreen HMI Interface for user-friendly operation
The gauges also include maintenance features, such as cleaning doors for easy service and calibration, making them highly adaptable to the high-temperature, debris-prone steel manufacturing environment.
Software Integration: MG Apps
The MG5 system incorporates MG Apps, a suite of advanced measurement software tailored for efficient data display and storage. The interface allows operators to:
- Track Coil ID and relevant parameters for streamlined coil tracking
- Generate real-time run charts that reset at coil changes
- Export comprehensive coil reports in PDF format
Automation and Data Handling
The MG5 system integrates seamlessly with factory systems, supporting:
- PLC Integration with Allen-Bradley, as well as Siemens S7, and Omron protocols
- Auto Start/Stop Functionality based on coil type and line status.
- SQL-based Data Management and dedicated network interfaces for secure data storage
- Automated Reporting and Publishing for KPIs on client’s network
Operational Benefits
The MG5 system has provided substantial operational improvements, including:
- Real-time Thickness Monitoring for proactive quality control
- Automated Data Collection ensures continuous, uninterrupted measurements and simplifies operational workflow by reducing manual reporting
- Process Visualization for streamlined operations
- Low Maintenance Requirements due to accessible service points and automated cleaning systems
Future Capabilities and Expandability
The MG5 system’s modular design supports future expansion and scalability, with options for:
- Software Upgrades to enhance functionality
- Additional Measurement Parameters to meet evolving production needs
- Enhanced Reporting Options for greater data insights
- Integration with Emerging Technologies to support Industry 4.0 initiatives
Conclusion
This case study showcases the MG5 system’s resilience in addressing the needs of steel manufacturing, particularly for galvanized/galvannealed steel processing.
Automation and real-time data capabilities provide operators with valuable insights, helping to optimize production and maintain consistent quality standards. Mate Gauge remains committed to delivering innovative, high-performance solutions tailored to meet the evolving needs of the steel industry.
For more details on Mate Gauge laser thickness measurement applications, explore our industry solutions page or contact our team.