Development of an Online Measurement of Cleanliness on the Zodiac Galvanising Line

该项目的范围是开发一种测试方法，用于测量塔塔Zodiac镀锌生产线钢表面的污染膜，该生产线向Automotive客户供应镀锌薄带，用于冲压车身覆盖件。Zodiac镀锌生产线是生产过程中的最后一道工序，从钢水到厚度约0.7 mm的卷材需要数周时间；因此，需要获得良好的锌层以满足所需的腐蚀性能是至关重要的。带钢进入Zodiac后焊接到前一个线圈上，然后进行清洁、退火，然后在发货给客户之前涂上一层锌。在带材镀锌之前，钢材表面要进行清洁，以去除所有污染物；如果钢材上残留有任何微小的污染，随后的锌层将不会附着在钢材表面。为此，清洁部分很复杂，涉及化学应用和搅拌、表面刷洗、喷雾和干燥操作；优化去除先前轧制过程中遗留在带材上的任何污染。对生产线来说，能够实时测量表面清洁度是很重要的，即在生产线上。这将使响应问题的解决能够纠正与表面清洁度的任何差异。该项目是开发一种有效的在线测量设备，能够在涂层操作之前可靠地测量钢材表面的清洁度水平。环境构成一些挑战；在线设备将需要连续测量整个20T钢卷的长度识别有机和金属颗粒的水平量化残留水平在合理的测试区域上测试适应移动带材表面的能力检测非常低的污染水平，即薄层或孤立的颗粒。

The project scope is to develop a test method for measuring contamination films on the steel surface at the Zodiac galvanising line in Tata, which supplies galvanised thin strips to Automotive Customers for pressing into body panels. The Zodiac galvanising line is the final process in a production process that takes several weeks from liquid steel to a coil that is ~0.7mm thick; so the need to achieve a good zinc coating for the required corrosion performance is critical.The strip comes into Zodiac and is welded to the previous coil and then cleaned, annealed and then coated with Zinc before being despatched to the customer. Before the strip is coated in Zinc the surface of the steel is cleaned to remove all contamination; if any minute levels of contamination is left on the steel then the subsequent Zinc coating will not adhere to the steel surface.To achieve this the cleaning section is complex and involves chemical application and agitation, surface brushing, sprays and drying operations; to optimise the removal of any contamination left on the strip from the previous rolling processes.It is important to the manufacturing line to be able to measure the surface cleanliness in real time i.e. on the processing line itself. This will enable responsive problem solving to correct any discrepancies with surface cleanliness.This project is to develop an effective online measurement device with the capability to reliably measure the cleanliness level of the steel surface ahead of coating operations.The environment poses a few challenges;The online device would need to continuously measure throughout the length of a steel 20T coilIdentify levels of organic and metallic particlesQuantify the level of residueTest over a reasonable test areaAbility to accommodate the moving strip surfaceDetect very low levels of contamination ie thin layer or isolated particles.