Quality and process monitoring system based on surface and internal defect detection for hot and cold wire (MONWIRE) : final report

The main objective of the project is to develop an integrated quality monitoring system for wire based on innovative defect inspection systems, with different techniques (eddy current, EMAT, CCD camera) and the support of technological database as quality and process data collector. The single objectives are the following: • Design and realization of a phase-array EMAT ultrasound system for surface and internal defect detection and classification and integration of this system into an online production process for cold drawing. • Design and realization of absolute dual frequency eddy current (AFDEC) system for surface defect. • Design and realization of visual inspection system based on CCD camera for surface defect and integration of this system into an online production process for hot wire rod. • Development and implementation of a new technological database for wire rod quality management with the following data: process parameters, defects and product data. Technological database will be provided with the software user interface for access and monitoring by quality staff from dedicated PC-base stations. • Development of off-line demonstrator reporting software providing an all-in-one surface quality diagnosis based on all data coming from the different sources and technological database This project has been carried out in collaboration among three research institutes (CSM, AMMR and BFI), two technological companies (DA and ROH) and three industrial sites (ORI, GRIES, and AMG).