Innerspec ROLLMATE Manuel utilisateur

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RM_A22 Page 1 of 35 ISO 9001:2015 Registered

Mill Roll Inspection System

ROLLMATE

Operator User Guide

This Material May Not Be Published, Rewritten,

or Redistributed Without Express Permission

ROLLMATE User Guide 
 
 
 
 
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Contents 
System Overview .........................................................................................................4 
Inspection Technique...................................................................................................4 
1. Types of Tests..................................................................................................................................4 
Quick Start ...................................................................................................................5 
1. System Inspection............................................................................................................................5 
2. Inspection Process........................................................................................................................... 5 
3. Inspection Results............................................................................................................................6 
Calibration / Verification ...............................................................................................8 
1. UT Calibration .................................................................................................................................. 8 
2. EC Verification.................................................................................................................................. 8 
Power Up/Down Sequence ..........................................................................................9 
Accessing ROLLMATE...............................................................................................10 
Operation Modes........................................................................................................11
1. Automatic Mode ............................................................................................................................. 11 
1.1. Communication panel ............................................................................................................ 11 
1.2. Selecting a Roll ID..................................................................................................................13 
1.3. Creating a Roll ID...................................................................................................................13 
1.4. Switching Users......................................................................................................................13 
1.5. Communications & System....................................................................................................13 
2. A-Scan (Oscilloscope) Mode..........................................................................................................15 
2.1. Restore Setups.......................................................................................................................16 
3. Report Mode................................................................................................................................... 16 
3.1. Loading an Inspection Record ...............................................................................................18 
3.2. Exporting Report Files............................................................................................................18 
4. View Mode......................................................................................................................................19 
HMI Main Screen........................................................................................................19 
1. Monitor ...........................................................................................................................................19 
2. Manual............................................................................................................................................19 
3. Settings ..........................................................................................................................................20 
3.1. Motor Adjust...........................................................................................................................20 
3.2. Position Adjust........................................................................................................................20 
3.3. Extra settings.......................................................................................................................... 20 
4. Roll Sensor Calibration .................................................................................................................. 21 
5. Sensor Input Data ..........................................................................................................................21 
6. Long-Range Sensor Calibration.....................................................................................................21 
7. Roll Level........................................................................................................................................22 
Automatic Controls.....................................................................................................23

ROLLMATE User Guide 
 
 
 
 
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Trouble Shooting........................................................................................................24 
Preventative Maintenance and System Health Checks..............................................27
1. Sensor Head ..................................................................................................................................28 
2. Refilling Procedure......................................................................................................................... 28 
3. Aligning the Sensor Head ..............................................................................................................29 
4. How to Remove a UT Cluster ........................................................................................................30 
5. How to Install a UT Cluster ............................................................................................................31 
6. How to Remove and Install a UT Transducer................................................................................32 
Customer Support Services .......................................................................................34
Spares........................................................................................................................35
1. Innerspec WebSales......................................................................................................................35 
 
 

ROLLMATE User Guide

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1. System Overview

ROLLMATE is an integrated non-destructive inspection system for the detection of defects in metallic rolls.

The system is designed to be installed on a grinder or lathe where inspection information is used to

minimize stock removal and machining time and increase the life of the roll by minimizing the amount of

material removed. The system provides a real-time defect map of the roll that is saved for later post-

analysis, tracking, and process control.

2. Inspection Technique

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).

The surface of the roll may be wet or dry before testing as couplant will be used during the inspection. The

surface conditions should be free of discontinuities such as spalls, missing material, grinder plunges, or

similar conditions that could cause damage to the sensor head during scanning.

2.1. Types of Tests

1. Axial Surface –Displays defects on the roll surface in the axial direction

2. Radial Surface –Displays defects on the roll surface in the radial direction

3. Axial Sub-Surface –Displays defects between 2mm and 60mm in depth in the axial direction.

4. Radial Sub-Surface –Displays defects between 2mm and 60mm in depth in the radial direction.

5. Shell Thickness –Displays the thickness of the shell along the length of the roll. *This test is

dependent upon the roll.

6. Bruise 1/Bruise 2 –Displays bruises detected in the roll.

7. Shell Disbond –Displays disbonds between the core and shell of a roll within a certain range of

shell thicknesses. The user will need to activate/deactivate the appropriate tests for the thickness of

the shell of the roll before the inspection.

ROLLMATE User Guide

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3. Quick Start

3.1. System Inspection

Each day/shift, the operator should complete the following maintenance and checks on ROLLMATE before

inspecting rolls:

•Wipe the sensor face with a clean soft cloth.

•Assure nothing is in the path of the ROLLMATE actuator.

3.2. Inspection Process

The following are steps for performing an inspection with ROLLMATE:

1. Load a Roll ID

Select the ID for the roll to be inspected. See section 7.1.4 Selecting a Roll ID.

2. Press the Start button.

With the roll rotating at a constant speed, the actuator will extend to the roll when its position is

within the set limits.

3. Scanning the roll.

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.

ROLLMATE User Guide

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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.

Colored areas indicate defects. The color corresponds to the test types listed at the top of the lower

window.

Bottom Window:

•Select the data to be displayed from the list across the top of the window.

Test Display Controls:

Flaw List –Displays a list of all flaws for the current roll.

Flaw Filter –Highlights flaw indications with size above a set threshold.

oRoll-3D displays a dynamic 3-dimensional image of the roll and its flaws.

oFlaw tests (Axial, Radial, Shell tests) display the maximum and minimum amplitude of the

UT signal for each rotation. Indications above the dashed threshold line will be shown as

defects in the C-Scan window with color matching the frame around the test type.

ROLLMATE User Guide

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oBruise tests (EC Surface) display the maximum and minimum magnetism for each rotation.

oShell 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.

Display/Hide the threshold line.

Note: Clicking the title bar for the current window will enable/disable these controls.

ROLLMATE User Guide

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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. Apply couplant on the two UT calibration blocks as shown below:

2. Click on the UT CAL button in Automatic Mode.

3. A Video with instructions on how to install the calibration fixture will start. Click “Accept”.

4. Install the calibration block as shown in the video.

5. Click “Yes” to begin the calibration.

6. If the calibration has passed. Click “Yes”.

4.2. EC Verification

The following steps are for the verification of EC sensors for ROLLMATE by confirming sensors read

appropriate values for hardness and softness chips.

1. Click the EC VER button in Automatic Mode

2. Instructions will display for zeroing, click Accept.

3. Wait for ROLLMATE to zero the EC sensors while in the air.

4. A video with instructions on how to install the verification fixture will start. Click Accept to start.

5. Wait for the verification for side A to be complete.

6. A video with instructions for sliding the fixture to side B will begin. Click Accept to start.

7. Wait for the verification for side B to be complete.

The couplant needs to encompass

all of the calibration notches

ROLLMATE User Guide

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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. Move the Power Disconnect Switch, located at the top-right of the DAC cabinet to the ON position.

2. Turn the E-stop button to the right and ensure the LED light is green.

3. Check and ensure that control valve(s) for couplant are open.

The following steps are to safely power OFF ROLLMATE:

1. Ensure that no scan is currently in progress.

2. Fully retract the sensor head (if extended)

3. Click “F11”then click on the “/” in the top right corner of the software. This will minimize the NDT-

WEB into a tab that can be re-opened in the bottom-left corner.

4. Next click on the power button in the bottom-right corner.

5. A menu will pop up. Click “Shutdown” this will power down the computer. Wait a minute for the

computer to power down.

6. Press the E-Stop in and move the Power Disconnect Switch to the OFF position.

Power Disconnect

Switch

ROLLMATE User Guide

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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.

3. Enter the operator’s username and password. The default username and Password is:

oUsername: admin

oPassword: admin

4. ROLLMATE will then start in Automatic mode.

Logging into ROLLMATE remotely:

1. Make sure ROLLMATE is powered ON. (Skip to step four if view mode is only needed)

2. From the system Press F11 to close out of the NDT-WEB, and right-click on the desktop to open

the file manager.

3. Navigate to /home/Innerspec/data/rollmate/server/customers and open the “ip_index”. Now type in

the IPs, one per line, which you want to have access to ROLLMATE. Save, and Restart

ROLLMATE.

4. Next open System Manager you will see the IP address for wired connections at the top of the

screen.

5. On a remote device, open the Google Chrome web browser and enter the IP address followed by

port “:4000” in the search bar, e.g., 10.10.8.23:4000

6. When the login screen appears, enter the operator’s username and password.

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