Authors: Kuldeep Agarwal Rajiv Shivpuri
Publish Date: 2013/09/13
Volume: 26, Issue: 4, Pages: 785-800
Abstract
Steel bar manufacturing process is a multistage process in which melted steel passes through multiple steps to form into a bar or rod of varying diameters The most common cause of rejection of such products is the surface defects such as seams scales cracks etc Often automated inspection in the form of image analysis is done to predict the formation of such defects These inspections suffer from the fact that they do not include the process information and hence are not very reliable This paper presents a novel methodology of prediction of surface defects in bar manufacturing In this method the surface images obtained by inspection methodology are decomposed into individual defects based on process knowledge These are then decomposed into the physical quantities affecting them which are decomposed into design parameters on rolling mill To achieve this decomposition Bayesian hierarchical modeling is used Data collected from sensors installed on rolling mill are used for model building and design After the model is built it is converted into an automated system called Diagnostics on Rolling Mill DORM DORM is installed on rolling mill and its performance is evaluated for several days It is found that the model performs very closely with manual inspection and predicts surface defects with good accuracy The Bayesian model also gives an insight into process parameters and physical quantities which affect the individual defectsThe authors would like to thank all the personnel involved in the data collection and implementation at Steel Plant especially OG Technologies Part of this work was funded by a grant from the STTR program of the National Science Foundation IIP0646502 The Bayesian formulation was supported under grant from NSF CMMI Engineering Design and Innovation Group Grant 1000330
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