How can image processing be used in continuous steel processes for early detection of quality deviations?

Inline camera-based inspection enables continuous monitoring of geometric features directly in the process without relying on downstream sampling inspections. With ibaVision, image data from a high-speed camera is analyzed and converted into measurable parameters such as diagonal differences. These “visual signals” are integrated into ibaPDA and trended synchronously with process data. This allows deviations to be detected early and immediate corrective actions to be taken.

How can visual process data be combined in real time with classical PLC and measurement data?

The integration is achieved by converting image information into numerical process signals that are directly fed into the data acquisition system. ibaCapture records the video sequences, while ibaVision calculates relevant features and transfers them as process values to ibaPDA. There, this data is processed synchronously with PLC and sensor data and stored long-term. This creates a consistent, time-synchronized data model for analysis and quality evaluation.

How can image-based condition monitoring reduce scrap in metallurgical processes?

Image-based condition monitoring enables early detection of geometric deviations that may later lead to scrap or disturbances in rolling processes. With ibaVision, critical parameters such as diagonal differences are continuously calculated and trended in ibaPDA. When predefined thresholds are exceeded, immediate alarms are triggered via a virtual traffic-light logic. This allows defective strands to be removed early and prevents process disruptions.

What are the benefits of synchronizing camera and process data for root cause analysis?

Time-synchronized linking of image and process data enables precise root cause analysis of quality deviations. With ibaVision and ibaPDA, visual events can be accurately correlated with thermal and mechanical process states. ibaAnalyzer additionally allows combined evaluation of trends and image snapshots in historical context. This significantly accelerates and improves the reliability of root cause analysis.

How can visual measurement values be integrated into an existing process control system and used for operator guidance?

Visual measurements are converted into standardized process signals through image analysis and integrated into ibaPDA. These values are available there like conventional measurement channels and can be monitored in real time. Via ibaQPanel, they are provided as an HMI-oriented visualization including trend display and traffic-light logic. This creates a direct link between image processing, process monitoring, and operator decision-making.

Increasing Product Quality by Means of Visual Signals: Online Process Monitoring With ibaVision

Continuous casting is a semi-continuous procedure for manufacturing steel blocks. The molten liquid metal is poured in the mold and pre-cooled, so that the strand has a solid shell of a few centimeters and a large part of the cross section still is in a liquid state. The strand is guided by the machines over strand guide rolls and is afterwards cooled. After it has solidified, the strand is cut on the out conveyor in the desired length by means of a cutting torch.

Without real-time monitoring, the geometry of the cast billets can only be measured on a random basis after cooling. Non-squaered billets and a deviation in the process state can only be detected much later in the process.

This is prevented by continuously monitoring the production plant with an image processing system. The process efficiency and also the product quality are increased with a lasting effect.

Increase

product quality

Higher

test density

24/7

process state monitoring

A vibrant red-hot metal bar is shown in a dark industrial setting, with white lines overlaid digitally to indicate measurement.

The Technology

A camera that is installed behind the cutting torch records the front sides on the billets and provides ibaCapture with the video data. ibaVision processes the video sequences and first of all determines the corner points of the front side of the billet and calculates – using these data – the length and the difference of the diagonal. These values are fed in the ibaPDA process data acquisition system as so called visual signals. ibaPDA then creates a long-term trend of these characteristic values. Thus, ibaVision allows for determining numerical values that do not have sensorics. In case of a significant trend, thus a diagonal-difference above a pre-defined threshold, the operator is being alarmed by means of a virtual traffic light on the user interface. The defective billet can then be eliminated. Simultaneously, the settings of the plant are adapted.

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Image processing delivers information that no other sensor can get – and does so 24/7.

Daniel Gauss
Product Manager, iba AG

The process data can be visualized online by means of the data recorded with ibaCapture and ibaPDA. The data determined in real time with ibaVision are available like all the other process data. The data are displayed on the control panel via ibaQPanel, which combines the functionality of an interactive measurement value display and elements from the field of HMI.

In addition to the live video image of the camera, the snapshot with the diagonal calculation, the current trend of the visual signals, and the process quality is displayed by means of a traffic light. The offline analysis of the process data, the visual data, and the time-synchronously recorded video images can be done with ibaAnalyzer for the purpose of root cause analysis.

Schematic illustration of online process monitoring with ibaVision

Used Functions

The following functions of the iba system are used in this application.

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Frequently Asked Questions (FAQ)

How can image processing be used in continuous steel processes for early detection of quality deviations?: Inline camera-based inspection enables continuous monitoring of geometric features directly in the process without relying on downstream sampling inspections. With ibaVision, image data from a high-speed camera is analyzed and converted into measurable parameters such as diagonal differences. These “visual signals” are integrated into ibaPDA and trended synchronously with process data. This allows deviations to be detected early and immediate corrective actions to be taken.
How can visual process data be combined in real time with classical PLC and measurement data?: The integration is achieved by converting image information into numerical process signals that are directly fed into the data acquisition system. ibaCapture records the video sequences, while ibaVision calculates relevant features and transfers them as process values to ibaPDA. There, this data is processed synchronously with PLC and sensor data and stored long-term. This creates a consistent, time-synchronized data model for analysis and quality evaluation.
How can image-based condition monitoring reduce scrap in metallurgical processes?: Image-based condition monitoring enables early detection of geometric deviations that may later lead to scrap or disturbances in rolling processes. With ibaVision, critical parameters such as diagonal differences are continuously calculated and trended in ibaPDA. When predefined thresholds are exceeded, immediate alarms are triggered via a virtual traffic-light logic. This allows defective strands to be removed early and prevents process disruptions.
What are the benefits of synchronizing camera and process data for root cause analysis?: Time-synchronized linking of image and process data enables precise root cause analysis of quality deviations. With ibaVision and ibaPDA, visual events can be accurately correlated with thermal and mechanical process states. ibaAnalyzer additionally allows combined evaluation of trends and image snapshots in historical context. This significantly accelerates and improves the reliability of root cause analysis.
How can visual measurement values be integrated into an existing process control system and used for operator guidance?: Visual measurements are converted into standardized process signals through image analysis and integrated into ibaPDA. These values are available there like conventional measurement channels and can be monitored in real time. Via ibaQPanel, they are provided as an HMI-oriented visualization including trend display and traffic-light logic. This creates a direct link between image processing, process monitoring, and operator decision-making.