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Innerspec ROLLMATE Operator's Manual

Mill roll inspection system
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Mill Roll Inspection System
ROLLMATE
Operator User Guide
© 2022 Innerspec Technologies, Inc.
All Rights Reserved
This Material May Not Be Published, Rewritten,
or Redistributed Without Express Permission
RM_A22
Page 1 of 35
ISO 9001:2015 Registered

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  • Page 1 Europe - Spain, UK Asia - China www.innerspec.com Mill Roll Inspection System ROLLMATE Operator User Guide © 2022 Innerspec Technologies, Inc. All Rights Reserved This Material May Not Be Published, Rewritten, or Redistributed Without Express Permission RM_A22 Page 1 of 35...

  • Page 2: Table Of Contents

    4. Calibration / Verification ....................8 4.1. UT Calibration ..........................8 4.2. EC Verification..........................8 5. Power Up/Down Sequence ..................9 6. Accessing ROLLMATE ....................10 7. Operation Modes ......................11 7.1. Automatic Mode ..........................11 7.1.1. Communication panel ......................11 7.1.2.
  • Page 3 ROLLMATE User Guide 10. Trouble Shooting ......................24 11. Preventative Maintenance and System Health Checks ..........27 11.1. Sensor Head ..........................28 11.2. Refilling Procedure ......................... 28 11.3. Aligning the Sensor Head ......................29 11.4. How to Remove a UT Cluster ......................30 11.5.

  • Page 4: System Overview

    ROLLMATE uses ultrasonic transducers for the detection of surface and sub-surface defects and includes an electromagnetic technique for the detection of soft/hard spots (“bruises”). ROLLMATE can be used on all metallic rolls, both forged and cast (all grades and chemistries) with diameters greater than 10” (250mm).

  • Page 5: Quick Start

    After the sensor head has fully extended to the roll Software will say “ready to transverse” and the scan can begin by moving the sensor head across the roll. 4. End of Inspection ROLLMATE will stop when the sensor reaches the opposite set limit, or if the operator pushes the stop button. RM_A22...

  • Page 6: Inspection Results

    ROLLMATE User Guide 3.3. Inspection Results Data will be displayed in two windows: Top Window: • Displayed C-Scan (Inspection results displayed as a heatmap). • The X-axis is the distance along the roll. • The Y-axis represents the circumference of the roll.
  • Page 7 ROLLMATE User Guide Bruise tests (EC Surface) display the maximum and minimum magnetism for each rotation. Shell Thickness tests display a scatter graph indicating the thickness trend of the roll shell. Controls for Flaw Tests: Enables/Disables the test. Adds/Removes the results from the C-Scan (top) window.

  • Page 8: Calibration / Verification

    ROLLMATE User Guide 4. Calibration / Verification ROLLMATE uses two fixtures for calibration and verification. One fixture is used for calibrating the UT channels and one fixture is used for verification of the EC channels. 4.1. UT Calibration The following steps are for calibrating the UT sensors for ROLLMATE: 1.

  • Page 9: Power Up/Down Sequence

    ROLLMATE User Guide 8. Verification for the EC is complete. If either verification fails, refer to the troubleshooting section of this guide, or contact Innerspec Technologies for assistance. 5. Power Up/Down Sequence The following steps are how to safely power ON ROLLMATE: 1.

  • Page 10: Accessing Rollmate

    ROLLMATE User Guide 6. Accessing ROLLMATE ROLLMATE can be operated from the DAC cabinet or remotely from a device connected to the same network. Logging into ROLLMATE from the DAC: 1. After powering ON ROLLMATE, System Manager will boot. 2. Click “Go to NDT-WEB a login screen will be presented on the monitor.

  • Page 11: Operation Modes

    Report modes are all described in the following sections. 7.1. Automatic Mode ROLLMATE starts in Automatic Mode when the system is initially powered ON. This mode is used for automated roll inspection and creating/loading a Roll ID. 7.1.1. Communication panel The communication panel is found on the bottom left of the home screen.
  • Page 12 ROLLMATE User Guide The operation mode changes as you navigate through the different areas within the software. The status for communication with the arm “instrumentation box”. The status for linear and actuator position. RM_A22 Page 12 of 35 ISO 9001:2008 Registered...

  • Page 13: Selecting A Roll Id

    ROLLMATE User Guide 7.1.2. Selecting a Roll ID The following steps are for loading a Roll ID: 1. Click on the Roll ID button (lower left toolbar). 2. The Data Manager Menu will open up. 3. Click “Existing Rolls”. 4. Select the Roll ID for the roll to be inspected from the dropdown list.
  • Page 14 Enter the position the inspection carriage is reading. (Use correct units) • Move the inspection carriage to the middle of the roll and ensure the ROLLMATE position and the inspection carriage position match. Scan Direction: Tells the software which UT cluster in the sensor head is on which side.

  • Page 15: A-Scan (Oscilloscope) Mode

    There is also a “post-Last” button on the Main screen for manually sending the last records requested API data. For more information on setting up your REST API contact Innerspec for the REST API documentation. 7.1.5.5. Regional Select the desired measuring system: •...

  • Page 16: Restore Setups

    ROLLMATE User Guide Axial and Radial Sub-Surface channels Normal Beam channels 7.2.1. Restore Setups The Setup defines the gains used for the different channels given the material. To restore the setups to a past version the following steps should be followed: 1.
  • Page 17 Axial Surface, Radial Surface, Axial and Radial Sub-Surface, Shell Thickness, Shell Disbond both Bruise Channels. • ROLLMATE will begin creating a report of the record. RM_A22 Page 17 of 35 ISO 9001:2008 Registered...

  • Page 18: Loading An Inspection Record

    The user can view different reports/scans by selecting for NEXT and for PREVIOUS. • Open file manager, navigate to home/Innerspec/data/database/backups. There you will find the two .sql files. • These files can now be copied to removable media. Note: If you have multiple files to send you must repeat steps 3-5 and generate a SQL file set for each record.

  • Page 19: View Mode

    While the system is running you can also leave the HMI on the monitor screen, this screen shows all inputs and outputs received and sent from ROLLMATE, grinder, and software. This screen also provides the last sequence step performed, last retract sequence, and deviation. Deviation corresponds to how far above/below the actuator head is from the required target roll gap.

  • Page 20: Settings

    ROLLMATE User Guide 8.3. Settings 8.3.1. Motor Adjust The Motor Adjust screen allows the operator to define the parameters for the motor. Hover speed, accel/decel, and jog speed can be adjusted here. The Filters set a time span for the roll sensors must be out of range before retracting.

  • Page 21: Roll Sensor Calibration

    ROLLMATE User Guide 8.4. Roll Sensor Calibration To calibrate, jog the sensor head to a position 1 to 3 mm away from the roll. The X1, X2, Y1, and Y2 fields contain slope-intercept values to scale raw analog input to user units.

  • Page 22: Roll Level

    5. HS Backups 6. Fifty 7. Forty-Four 8.7. Roll Level This page shows sensor 1 and sensor 2 readings and will display if the roll or rollmate sensor head is not level. RM_A22 Page 22 of 35 ISO 9001:2008 Registered...

  • Page 23: Automatic Controls

    (Start/Stop Bit) to ROLLMATE. Then ROLLMATE extends the actuator to the roll and returns a Head on Roll bit to the grinder. The grinder traverses ROLLMATE along with the roll. When the scan is complete, determined by the grinder, the Start/Stop bit is lowered and ROLLMATE retracts the sensor head, finishing the scan and displaying the scan results in real-time.

  • Page 24: Trouble Shooting

    ROLLMATE User Guide 10. Trouble Shooting Below is a list of ROLLMATE errors that can happen and their causes and repairs that have been documented. Symptom Possible Cause Repair Ensure that there is adequate couplant/UT gel between the calibration Lack of couplant.
  • Page 25 ROLLMATE User Guide Jog grinder carriage ROLLMATE is out of until ROLLMATE is over roll range barrel. Check the actuator for possible obstructions or blockages, and clear as necessary. E-Stop is activated Deactivate E-Stop by pulling Actuator is inoperable out the E-Stop button and clearing on HMI.
  • Page 26 ROLLMATE User Guide Check for water on the face of the sensor and wipe if needed. Check for damage to the The sensor head crashes Long range sensor sensor face. into the roll (continued) malfunction Check for sporadic readings on the HMI.

  • Page 27: Preventative Maintenance And System Health Checks

    ROLLMATE User Guide 11. Preventative Maintenance and System Health Checks Preventative Maintenance Schedule Part Activity Frequency Verify the UT transducers are UT transducers Daily operating well by running calibrations regularly. Ensure the sensor head moves Daily smoothly on the actuator.

  • Page 28: Sensor Head

    6 fluid ounces of water to fill. Good quality water, free of particulates and other contaminants should be used. When experiencing temperatures below freezing, the fluid pockets should be protected. Before performing maintenance on the sensor head, please contact Innerspec as needed. 11.2. Refilling Procedure 1.

  • Page 29: Aligning The Sensor Head

    ROLLMATE User Guide Note: When refilling the UT cluster, it is recommended you remove it from the sensor head. Valve Open/Close Fill Ports 11.3. Aligning the Sensor Head The following instructions are for properly aligning the Sensor Head 1. Remove the two UT wear shoes from the test head. Each wear shoe is held onto the test head via 2 M5 screws on the face of the test head.

  • Page 30: How To Remove A Ut Cluster

    1. Lower the sensor head down so it can be worked on. 2. E-stop the ROLLMATE and disable the grinder the system is attached to. 3. Remove any side panel to the sensor head as needed. The front and back panels are held in by six M4 buttonhead cap screws.

  • Page 31: How To Install A Ut Cluster

    ROLLMATE User Guide 6. Remove the four screws on the faceplate holding the UT cluster in place. 7. Unplug the UT cables connected to the UT cluster transducers. 8. Lift the UT cluster and rotate as needed to remove it from the sensor head.

  • Page 32: How To Remove And Install A Ut Transducer

    ROLLMATE User Guide 6. Install the wear shoe. Each wear shoe is held onto the test head via 2 M5 screws on the face of the test head. Ensure the water ports on the wear shoe are on the side the water hoes are connected to the sensor head.
  • Page 33 ROLLMATE User Guide 5. Pull out the two UT transducers. 6. Pull off the UT tops. They will be two pieces. 7. Under the UT tops will be a gasket. Remove the Gasket. 8. Under the Gasket will be an O-ring in each UT transducer slot. Remove the O-rings.

  • Page 34: Customer Support Services

    See section 11.5. 12. Customer Support Services Innerspec offers a comprehensive list of services to help ensure the best performance of their inspection systems, including remote and on-site service options. Requests for support, including return material authorizations, should be submitted using Innerspec’s help desk.

  • Page 35: Spares

    ROLLMATE User Guide 13. Spares 13.1. Innerspec WebSales Spare parts and consumable items are available from Innerspec Technologies using the Innerspec WebSales tool. Innerspec WebSales tool allows customers to: • View purchased equipment lists. • Shop for parts. • Update your account information (billing/shipping address, password, etc.).

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