Quality Data Recording with ibaQDR
Length-based Quality Data in Meter Resolution
Continuous processing lines need length-based quality data for product qualification. The quality data recording system ibaQDR acquires data time-based at different measuring locations and assigns the measurement values precisely to the length position of the product.
- Recording system for quality data, based on ibaPDA architecture
- Technological process description of strip processing lines
- Length normalization to the final product (exit coil) and synchronization of all measurement data
- Consideration of strip elongation in the process and all cuts
- Standard length resolution: 1 m (fully adjustable incl. unit)
- Scalable number of measuring locations and signals
- Integration of ibaCapture-CAM data
- Additional time-based recording as an option
- Data storage in iba *.dat format related to the exit coil and additional to the entry coil
- Data flow integration with ibaDatCoordinator, ibaAnalyzer-DB and report generator
Length-based Quality Data in Meter Resolution
Quality data acquisition of today, for every manufacturer of high-quality products is an essential part of the production process. The quality data recording system ibaQDR is smoothly integrated in ibaPDA as an add-on. The user has the same look-and-feel like in ibaPDA. This offers a transparent quality data acquisition and an efficient data management.
A product (coil)-related analysis of quality data makes sense, if the relevant measured values can be mapped exactly to the product. In case of long products, a length-based mapping of the data over the product is usually required, e. g. feet-wise or meter-wise. ibaQDR does this mapping based on the previous time-based recorded data in combination with accurate data of the material tracking. The successively recorded (time-based) data are mapped exactly to the product at the point where they have been measured.
The system has been optimized for rolling mills, processing lines and inspection plants within the metal industry but it can be used as well in other industrial sectors.
Quality relevant data are for example:
- Product dimensions (width, thickness, ....)
- Cross profiles (strip coating, thickness cross profile,...)
- Production parameters (rolling forces, tensions, temperatures ...)
- Reference values and consumptions figures etc.
Mapping of measurement values and product position using the example of a processing line
Easy Configuration and wide Range of Interfaces
ibaQDR is based completely on ibaPDA and the iba hardware and interfaces. Therefore the whole iba connectivity is available. The signals to be measured are configured in the same I/O manager as in ibaPDA.
The ibaQDR recording functions is to be configured in a user friendly GUI.
The production line is divided into several sections (measuring locations), where the quality relevant data are acquired. At first, the measurement data are recorded separately based on the measuring locations, together with the material ID and the position (length) of the strip in relation to the measuring location provided by the material tracking.
There exist as many temporary data files as measuring locations. When the product (coil) is finished (e.g. defined by shear cut) the measurement data are extracted from the temporary single files based on the material ID and the length positions and will be written into a new file – the QDR data file. All measurement values that belong to the recently produced strip based on the final product length in respect to the material elongations caused by the production process are stored in this file in a normalized way.
In addition (optional) it is possible to save QDR data defined by the entry coils too.
That means that parallel to the exit coil data files, a data file for each entry coil will be also generated by ibaQDR.
On the different measuring locations, time-based and entry coil related measurement files are generated. ibaQDR generates an exit coil related file, in which the data are mapped exactly to the length.
Online Status Display
The status of the recording is monitored continuously in a special window showing the current material-ID and length at the measuring location, no matter whether a recording is running or not. Furthermore, file name and elapsed time are displayed. This is valuable information, particularly during commissioning of the system.
Configuration of the measuring location
Besides the name of a measuring location further information is to be entered in the configuration
dialog, such as control signals from material tracking, like material-ID and actual length position.
Moreover, the assignment of quality relevant signals and measuring location has to be done here with a mouse click. Two actual length values (entry and exit) can be configured for each measuring location in order to provide an appropriate consideration of an elongation of the product, for example at rolling stands.
Further special types of measuring locations are available, such as measuring location before welder or measuring location with (length) offset.
Scalable System Size
An appropriate number of measuring locations, depending on the license, can be defined throughout the line.
Another arbitrary number of measuring signals can be assigned to each measuring location. An ibaQDR system can perform also the (time-based) data recording for maintenance in respect to the size of the plant. In case of large scale plants and high availability requirements we recommend a separated ibaPDA system in addition to the ibaQDR for maintenance and fault analysis.
Analyzing with Standard Tools
The data files which are generated by ibaQDR can be analyzed and displayed with ibaAnalyzer. The results of the analysis can be published either on paper or in various files and sophisticated reports by means of the integrated report generator.
Quality Data Management
Using the software ibaAnalyzer-DB the recorded data can be provided to higher level systems, such as MES (Manufacturing Execution System), DataWarehouse or individual applications in a plain and transparent database structure. In ibaAnalyzer-DB statistical parameters or KPIs (Key Performance Indicators) can be derived with maximum in transparency directly from the high resolution data and made available for other systems.
Supported data base systems are Oracle, SQL-Server, DB2-UDB, PostgreSQL, MySQL and other ODBC databases.
As ibaQDR works in close relation to the segment mapping of the automation, a detailed knowledge of the functioning of the automation is required for the configuration. Therefore we recommend the integration of the system through a qualified supplier or together with support services (consulting, training, support).
Acquire and analyze data
ibaPDA and ibaAnalyzer are the essential tools to acquire and analyze data.
Hardware to acquire data
Our standard tools for data acquisition