Vmx Dequs

Analyzes the surface, finds and points out even minor defects, controls technical processes and equipment status.

Vmx Dequs is capable of:

avoid human
factor errors

perform high accuracy automated quality control

reduce multiple cost by detecting defects at the early stages sending timely notifications about failures and breaches in technical process

What does the product work with?

Vmx Dequs is a video analytics solution for monitoring the:

01

Product
quality

The system uses computer vision technologies. Scanning the product surface, it points out even minor defects: roughness, scratches, change in configuration, cracks, holes. When the reference surface parameters are set any deviation from it will be considered as defects: welds, shape or color. Vmx is capable of classifying the product and identify defects based on set parameters.

02

Production
processes

Vmx Dequs detects vapor, smoke, leaks, sparkles, changes in color or failures in equipment operation and shall give alarm. If the screen is off and the image of the camera is on, it means that everything is fine at production. If Vmx Dequs detects an incident it enables the corresponding monitor showing the real-time video, which is clearly visible.

03

Equipment
status

The video analytics system is capable to detect (easier than a man could do) any issues arising with equipment: from any small cracks on the tools and pipes to monitoring location of conveyor parts. This is a handy tool in planning routine shutdown and perform equipment maintenance.

Vmx Dequs: ECO – monitoring of non-routine emissions.

Vmx Dequs – product quality control at equipment surface.

Vmx Dequs – visual process control at key facilities.

vmx-dequs

Application cases
Vmx Dequs:

01

Elastic gum cubes quality control

The automated elastic gum quality control system includes video analytics, informs about defects, ranges defects and shows results on the dispatcher's screen. Defects from 2x mm shall be detected while the elastic gum passes the conveyor at 600 mm/s. Vms system examines the cube from 6 sides defining object geometry and differentiating between defects and artefacts (the cameras with built-in quality control algorithms are unable of doing). Moreover, Vms Dequs shall be built in MES to assist in removal of defected cubes.

02

Quality control of the rolled metal strips

There is no need to waste metal at final preparation and bear additional cost as far as all issues may be detected at the first cold rolling. The system analyses strip edges to detect 1x1 edge defects: cracks, tears, breaks, holes, i.e. all inadmissible defects. Vmx Dequs defect chart in the database helps to define if the defect shall be crossed cut or stamped out. This chart allows to slow down and shutdown the APR at non-critical defects for stamp outs and for critical defects for shears. The system is operated at 60-80°C at the speed up to 15m/c.

03

Control of position and geometry of the rolled sheet

Vms Dequs is used for reduction of the strip breakage in the interstand gaps of the hot rolling mill. It accurately determines the boundaries of the rolled strip and the presence of its displacement and bends. It effects the breaks, which means they should be detected as quickly as possible. The system not only copes with determining the position and geometry of the sheet at the moment, but also controls the Mill Control System to straighten the strip. And even droplets of splashes falling on the camera ( the strip is cooled with water) - does not prevent Vmx Dequs from coping with its task.

04

Control of environmentally hazardous emissions

Vmx Dequs is able to work not only inside the workshop - indoor, but also outside - outdoor. In the case of monitoring environmentally hazardous emissions, the Vmx System monitors emissions from the company's pipes from afar, where it clearly recognizes the pipes and their contents. At the same time, the system works around the clock, separating steam, smoke, fire, and “red tails” among themselves. All this allows not only to instantly respond by adjusting the technological process that caused the release, but also to keep statistics within the framework of the standard - how much has already been released into the atmosphere per day / week / month.

05

Slag control for Ultra Disperse Particles

In the process of desulfurization, slag appears on the surface of the tank with molten metal. Deslaggering has to be performed to ensure the high quality of steel. At the same time, it is important to stick to deslaggering standard rate - up to 2 tons of metal per tank. The Vmx Dequs: HistControl system analyzes the slag removal process by ignoring the skimmer - the scraper that is used for deslagging- and analyzing the surface with the calculation of the exact purity index online. This facilitates the task for the shift workers in the cleaning process. In some cases, deslagging rates increased from 75% to 90%. The system paid off in 1 month and saved the company 20 million rubles in the first year.

06

Process scheduling

Hot steel is poured into the steel ladles, on laddle carriers moves around the workshop, where at the given points the crane lifts the ladle and carries it to the CCM - a continuous casting machine. At the same time, it is important to calculate the time for pouring steel into the ladle and transportation time it to the CCM so that the steel in the ladle maintains the required temperature, otherwise it will have to be reheated. To reduce the influence of the human factor in favor of automatic operations, automatic dispatching is used in the converter shop. The interactive mnemonic diagram reflects the current position of the key mechanisms and steel ladles, and the System automatically calculates the time required to fill the steel ladle with steel and feed it to the CCM.

07

Process control

Monitoring over several dozen monitors with the same type of processes day after day is not an easy task for human attention which may cause a blurry eye effect. In such a situation, it is easy to miss the problem at its very beginning. The Vmx Dequs: Monitor system blanks out all dispatcher screens and turns on only that monitor that detects an abnormal situation at a certain key process node.It is determined by visual signs: liquid spills, color changes, the presence of particle movement in the frame, steam, fire, the wrong position of the lever or cover, etc. This allows to respond to the situation quickly, solve problems with the root cause and significantly reduce the cost of equipment downtime and the technical process as a whole.

08

ARMIL Steel sheets quality control

ARMIL - is an automated desk for final inspection of steel sheets. This is what we are extremely proud of and this is our know-how. A software and hardware complex of its own design commissioned by JSC RT-Tekhpriemka (GK Rostec) autonomously analyzes the thinnest steel sheets for civil and military aviation. The system of multispectral processing and video analytics based on machine vision and artificial intelligence determines more than 20 types of the smallest defects from 0.3 mm in size with an accuracy of more than 97%. All this makes it possible to reduce the acceptance time and ensure quality of strategically important material for further military production.

09

Equipment status control

Allows to reduce the number of hours of equipment downtime, prevent accidents, and quickly notice the wear of key parts of equipment for partial replacement in time, without leading to long-term and expensive overhauls. The system scans the surface of the equipment looking for key elements. In the case of monitoring cracks 0.4 mm wide and 25 mm long on the surface, it monitors, among other things, the dynamics of crack change. Periodic scanning of the conveyor surface allows you to detect wear of components, missing fasteners, protruding fingers, etc., eliminating the human factor and providing high-quality production control.

More information about the software and terms of the client-specific license use is available at vmx@videomatrix.ru

Compatibility
with other products

If Vmx Dequs is used in combination with Vmx SILA, then not only the process shall be controlled, but also a  person will be controlled. In this configuration, the interaction of the employee with the equipment is controlled, for example, whether lid is opened in time, or the lever is duly turned.

As a result you receive:

01

the ability to minimize manufacturing defects that may result in production of only high quality products

02

reduction of cost associated with equipment downtime

03

reduction of the risk of accidents

04

proper response time to incidents

05

impartial assessment of quality at the highest level

06

monitoring in hazardous environment, of example in explosive zones

07

optimization of company resources for equipment repairs