Quality By Vision inROLL HR: Tooling Profile Scanner

Worn or incorrect roll and chuck profiles can lead to bad double seams, machinery breakdowns, product holds and customer complaints. Putting incorrect or worn Rolls or Chucks in the seamer without inspection can produce bad seams – which can stop production (or worse).

Using a non-contact, laser based profiloscope – the inROLL is able to scan profiles of seaming Rolls and Chucks (or other tooling – including carbide and ceramic tools) automatically, easily and quickly. The system can be used for acceptance testing for new seaming rolls or chucks, for quality assurance purposes for used tooling and for stress analysis.

inROLL is the first dedicated computerized automatic, non-contact seaming Roll and Chuck gauging system. By scanning the profile, it is capable of detecting defects in the profile, analyze angles, radius, measuring distances and automatically measuring the differences between a roll’s specification and the roll’s actual profile. This system replaces optical comparators, projectors and other techniques for manually (and subjectively) comparing contour profiles for rolls, chucks and other tooling.

Using a micrometric table, the operator can position practically any tooling into view. Once positioned correctly, the operator captures the image and the software automatically analyzes it against a given standard graph, which can be either a previously scanned image (the same tooling when it was brand new) or even a CAD drawing!

The operator can:
• Zoom in and out of the profile
• Find any radius, angle or distance on the profile
• Export the profile to CAD or compare it with a CAD drawing
• Import a reference profile from a CAD drawing(including regions of interest)
• View automatic measurements (compare it to the spec)

Each standard can have “regions of interest”, which allows the operator to automatically measure radii and angles anywhere on the profile. The measurements can be integrated into reports and inspected for variations over time, both between different rolls and for the same roll at different measurement positions.

For rolls, the system will automatically detect roll depth, height and length. For chucks, the system automatically measures the chuck width, angles and more. Both first and second operation rolls can be inspected easily. The system can also be used to inspect can necks, flanges and other characteristics. The system can print out graphs which can be compared with the original drawings.

Customers using the inROLL system are able to quickly return their investment by evaluating rolls and chucks already in storage. When companies have problems with a particular head, they often choose to replace the roll or chuck (or not replace it because it hasn’t reached it’s can count). Often, these “suspicious” rolls and chucks are placed in a storage with other rolls and chucks that may still be good.

No one is truly sure if these are good or bad, and because of their high costs they are typically not thrown out. Customers who used the inROLL system on such rolls found that between 70% and 80% of their rolls were still in good shape, and were able to reuse them. Other rolls were thrown away or returned to the manufacturer in situations where they did not match the original requirements. As rolls are quite expensive, this is a great way to quickly recover the cost of the system almost instantly!

Manufacturing often produces different results from the original design. The inROLL allows you to import your diagrams directly from Auto CADTM or other CAD software. Regions of interest are extracted automatically based on the design and the actual profile can be accurately compared with the original drawings!

Some manufacturers may have identical roll designs with different catalog numbers. Reduce inventory by combining all rolls with identical profiles into one part number!