In the CCR3 Department, after copper plates from the refinery are melted, they are passed through a furnace to form cast bars. These bars are gradually reduced in size through rollers, eventually forming copper rods that are stored in large coils for delivery. Monitoring the surface quality of the cast bars is critical to ensure the integrity of the copper and identify any potential issues with the melting or furnace process. This project aims to detect surface defects on the cast bars as they pass through a specific point in the production passage. Defects, typically blackish in nature, indicate potential problems in the copper melting process or furnace quality. Identifying these defects early allows for timely intervention and quality control.
Key Features
01
System Configuration
Camera Setup: Four cameras are positioned around the conveyor belt approximately 2 to 2.5 metres away from the cast bar. These cameras are strategically placed to capture:
The edges of the rectangular cast bar cross-section.
The sides of the cast bar to ensure complete surface coverage.
The cameras provide high-resolution images to detect even the smallest surface defects.
02
Network and Server Connection
The cameras are connected to a central server using optical and networking cables, ensuring high-speed data transmission from the camera system to the processing unit. The server processes the camera feeds and handles defect detection in real-time.
03
Defect Detection Process
The system continuously monitors the surface of the cast bar as it moves along the conveyor. The key features include:
Defect Detection: The system identifies blackish defects on the surface of the cast bar. These defects are indicators of potential quality issues with the furnace or melting process.
Live Monitoring: Operators in the control room can view live camera feeds, enabling real-time monitoring of the cast bar's surface condition.
Hooter Alerts: When a defect is detected, an alert system (hooter) is triggered in the control room to notify the operators of the issue, prompting immediate attention.
04
Data Storage and Reporting
• Image Storage: All frames showing detected defects are stored on the server. These images are crucial for reviewing defects and troubleshooting the melting or furnace processes.
• Database Logging: The system logs all detected defects in a MySQL database, storing relevant information such as the type of defect, time of detection, and other associated data. This allows operators and engineers to analyse trends and address recurring quality issues.
05
Defect Detection Process
A user interface is provided in the control room, offering the following functionalities:
Live View: Continuous live camera feeds are displayed, enabling operators to monitor the cast bar's surface in real-time.
Defect Notification: Detected defects are highlighted on the interface for easy identification and immediate action.
Defect History: Operators can access a log of past defects, complete with images and data for further investigation.
Conclusion
The Cast Bar Surface Defect Detection System enhances quality control in the CCR3 department by automating defect detection in real-time. With the integration of a robust camera network, real-time alerts, and detailed defect logging, the system ensures that surface quality issues are identified early, enabling operators to take corrective action and maintain production standards.
