Thickness Gauging - C-frame gauge

Gauging for non-ferrous foil & strip

The Millmate Thickness Gauging system, based on the Pulsed Eddy Current technology, opens up new dimensions in metal foil and strip gauging. Weak magnetic fields are used for the measurement and the gauge is completely safe to use.

The technology is completely insensitive to anything in the measuring zone, except the metal strip. The gauge will therefore measure true strip thickness unaffected by coolant, dirt, steam, air temperature variations, etc.
Since the MTG is material-independent there is no need for alloy compensation and calibration.
Measurement can be done close to the rollgap, without removal of emulsion.

Our offering

Gauge head

System concept

Cyber security

Options

Gauge head - PMGG123

Contact-free measurement and a robust design makes The Millmate Thickness Gauge a thickness gauge that will provide high availability and hassle-free operation in harsh industrial environment.

The gauge has no fragile parts or parts that will age. Therefore the MTG provides a superior long-term stability. From a maintenance point of view the system is the most dependable thickness gauge on the market.

An aluminium-bronze housing is used as a case for the measuring coils and the electronics. The measured thickness deviation and other signals from the gauge are transferred to a control unit via fieldbus communication.

Only a few certified plates (included in delivery) are needed to calibrate the system to cover the complete measuring range. After calibration at commissioning, the system measures any non-ferrous material or alloy without additional calibration.

+ Data

Type	PMGG 123-S	PMGG 123-F
Min. thickness
for low alloyed copper and aluminum	0.010 mm (foil mode)	0.010 mm (foil mode)
	0.025 mm (normal mode)	0.025 mm (normal mode)
for high resistivity material (450 nΩm)	0.040 mm (foil mode)	0.040 mm (foil mode)
	0.100 (normal mode)	0.100 (normal mode)
Max. thickness	15 mm	6 mm
Repeatability	±0.03% (not better than 0.3 μm)	±0.03% (not better than 0.3 μm)
Accuracy	±0.05 % (not better than 0.5 μm)	±0.05 % (not better than 0.5 μm)
Total Accuracy Standard mode (relative permeability=1.0)	Non-ferrous metals	Non-ferrous metals
strip thickness > 2.0 mm	±(0.05% + 2 μm)	±(0.05% + 2 μm)
strip thickness < 2.0 mm	±(0.1% + 1 μm)	±(0.1% + 1 μm)
Min. strip width	250 mm	140 mm
Strip position
for changes faster than 1 mm/s	±5 mm	±3 mm
for changes slower than 1 mm/s	±10 mm	±8 mm
Strip slope	±3°	±3°
Step response	15 ms	15 ms
Operation temperature	+5 - +55°C	+5 - +55°C
Degree of protection	IP 65	IP 65
Power supply (from the control unit)	24 V DC, max. 3 A	24 V DC, max. 3 A
Dimensions (W x D x H)
Gauge without holder	198 x 425 x 302 mm	160 x 425 x 293 mm
Weight
Gauge	50 kg	37 kg
Gauge holder	30 kg	30 kg

+ Application

The heavy-duty design of the gauge and the stability of the measuring principle makes the Millmate Thickness Gauging System superior in applications that previously were considered impossible. Measurement can be done close to the rollgap, without removal of emulsion.

Material
The MTG is designed for dependable gauge measurement on a wide range of non-ferrous materials with different alloy compositions and resistivities, i.e. aluminium, copper, zinc, tin, lead and beryllium.

Single or Double gauge system
In reversing mills it is very common to use thickness gauges on both sides of the mill. The MTG system offers two different control units, one for handling a single gauge and the other for handling two gauges. The user-friendly operator unit has a display function for double gauge configuration. The operator can see the thickness gauge deviation graphs, one for each gauge, on the same menu page.
The feature with double gauge systems can also be valuable in applications like tandem mills or slitting lines.

Sledge
As an option ABB offers a sledge design with a number of stroke lengths. It is the difference between strip width (min./max.) used in the mill that mainly decides how the sledge should be designed for each specific application. The sledge motion range should be designed so that the gauge can be fully withdrawn from the strip.

+ Pulsed Eddy Current Technology

The Millmate Thickness Gauging system is based on the Pulsed Eddy Current technology, which uses magnetic fields for measurement of the strip thickness. The interaction between an applied magnetic field and the electrically conductive strip indicates the thickness - without influence from material composition or conditions in the measuring gap.

Phase 1: Transmitting

An electric field is generated with a transmitting coil
The field is applied until it fully penetrates the strip
The field "energy" is stored in the air gap and in the strip
The amount of energy stored in the strip depends on the thickness alone - not on resistivity

Phase 2: Distance measurement

Fast air response just after transmit field is swithed off
The measurement of air gap energy corresponds to distance between coil and strip
Pulse time t1 is typically less than 5μs

Phase 3: Resistivity measurement

Response from the surface area of the strip
The measurement starts when the air gap signal has declined
The measurement of the surface response corresponds to resistivity and is dependent on the speed of the field leakage out of the strip

Phase 4: Thickness measurement

Response from the whole strip
The measurement starts when the air gap signal has declined (phase 3 is included in phase 4)
The measurement of the whole strip corresponds to the complete energy stored in the strip, and continues until the strip response has almost declined (t3)
The measurement corresponds to the strip thickness
The resistivity does not affect the level of the whole strip response
The tail part after t3 is calculated with the use of the resistivity part

System concept

Control unit - PMGA12*

The Millmate Thickness Gauging System is an intelligent measurement system and measures as accurately in the production process as in the laboratory.

The Control unit is used for integration with superior systems to enable automatic operation. For system integration there is a choice of integration interfaces:

Profibus DP fieldbus communication
Network communication via OPC
Discrete I/O-signals

The Control unit also handles communication with the gauge for measurement data, state control and error handling as well as implements vertical and horizontal automatic position control functions.
There are Control unit versions for one or two gauges and with wall or floor cabinets.

+ Data

Type
Single gauge system	PMGA 121
Double gauge system	PMGA 122
Supply voltage	115/230 V +10/-15%
Power consumption	300 VA
Thickness output	±10 V
Digital inputs	24 V nominal, opto insulation
Digital outputs	24 V/0.5 A, opto insulation
Operation temperature	+5 to +45°C
Dimension W x D x H
Elkapsling wall cabinet	800 x 300 x 800 mm
Elkapsling floor cabinet	800 x 400 x 1900 mm
MNS Select floor cabinet	840 x 656 x 2225 mm
Weight
Elkapsling wall cabinet	75 kg
Elkapsling floor cabinet	250 kg
MNS Select floor cabinet	250 kg
Protection class
Elkapsling wall/floor cabinet	IP 54
MNS Select floor cabinet	IP 21/IP 54

+ System interface

The Millmate Thickness Gauge System can easily be connected to AGC systems, based on feedback, feedforward and mass flow control.

Network communication
OPC (www.opcfoundation.org) can be used as an alternative to I/O-signals for integration. The system supports OPC 6.1 Data Access over an optional Ethernet local network. To gain access to measurement data and system set-up, a computer with OPC-client functionality can communicate with the Control unit via an optional OPC-server.

Profibus-DP
As an option, the MTG system can be equipped with a Profibus-DP slave interface for communicating with e.g. the rolling mill control system. The Profibus-DP interface provides fast transfer of measurement data. It can also be used for setting up nominal thickness and for remote control of system settings and gauge movement.

Single or Double gauge system
In reversing mills it is very common to use thickness gauges on both sides of the mill. The MTG system offers two different contol units, one for handling a single gauge and the other for handling two gauges. The user-friendly operator unit has a display function for double gauge configuration. The operator can see the thickness gauge deviation graphs, one for each gauge, on the same menu page.
The feature with double gauge systems can also be valuable in applications like tandem mills or slitting lines.

Hydraulic Valves

+ Data for Hydraulic Valves

Type	Hydraulics
Working pressure	50 bar
Input pressure	max 160 bar
Flow	5 l/min
Pressure switch	40 bar
Pressure fluid	Mineral oil DIN 51524 (HL, HLP) Phosphate ester (HFD-R)
Sealing	Viton

Air regulator

The air regulator filters the air and controls air pressure in the gauge. The air is used for internal temperature control and provides over-pressure to prevent coolant, etc., from entering the gauge.

+ Data for Air regulator

Air regulator
Supply pressure	5 to 16 bar (72,5 to 232 psi)
Air consumption	5 dm³/s (11 cfm)
Air quality requirement	Acc to PNEUROP
Particle class 3	Particle size max 1 μm (40 μin), particle content max 5 mg/m³
Oil content class 3	Max1 mg/m³
Condensation class 3	Condensation at +10° C (50 °F)

Cyber Security

ABB approach to Cyber Security

ABB provides the defense-in-depth security required for digital solutions in mission-critical applications and industries.
A common standard is applied for all ABB products and system with rigorous testing performed by specialists.

HMI based on Windows 10 IoT

Active firewall configured to block all incoming connections
Hard drive locked down for writing, a reboot resets the HMI
User preferred malware protection to be added
Periodic Windows patch packets service – tested with application software

Controller based on Windows 7 Embedded Compact

WEC7 is a real-time OS - normal Windows program cannot be executed
Much less vulnerable
External communication designed as a normal Firewall
Only 2 available ports for defined external interfaces:
1. Modbus/TCP and OPC DA
2. VIP/TCP

Options

Sledge

The gauge holder is mounted on a sledge that enables the gauge to move horizontally into the measuring position. ABB offers a standard sledge solution with a number of stroke lengths. Strip width (min./max.) determines what kind of sledge should be used. Consult your local ABB representative for further details.

Enhanced protection kit
In applications where the gauge may be exposed to severe strip breaks, other high impact forces, or fires, the optional enhanced protection kit is recommended.

The enhanced protection kit consists of a stainless steel hose and hood for the gauge and the gauge holder. The kit enhances the mechanical, chemical, and fire protection of the gauge.

Clad measurement function

With the optional clad measurement function the Millmate Thickness Gauging system measures the thickness of multi-layer aluminium clad strip, this with superior accuracy.

The built-in clad function only requires information about the clad layers' nominal thicknesses and resistivities. The resistivities can be determined with support functions included in the scope of supply. The start-up and commissioning routines for the clad function are straightforward and easy to use. The need for test plates is limited. New types of clad material can easily be added, without the need for time-consuming test and calibration procedures.

+ Data for Clad measurement function

Data	Standard Gauge	Foil Gauge
Accuracy for strip thickness < 2 mm*	±(2.0 µm + 0.1 %)	±(2.0 µm + 0.1 %)
Accuracy for strip thickness > 2 mm*	±(3.0 µm + 0.05 %)	±(3.0 µm + 0.05 %)
Thickness range	0.035 - 15 mm	0.025 - 6 mm

*Provided information about clad layer parameters is correct

Resistivity measurement function

With the optional resistivity measurement function, the Millmate Thickness Gauging system offers a unique possibility to continuously monitor material property changes.

Material property measurement on metal strip are normally done in laboratory according to a spot test procedure. The MTG, with built-in resistivity function, measures the resistivity on-line with an accuracy equal to the best available lab instruments.

+ Data for Resistivity measurement function

Data
Accuracy (at 20 °C)	±1.2 % < 0.1 mm (of resistivity reading for thickness)
	±1.0 % < 0.1 mm (of resistivity reading for thickness)
Measuring range	16 - 450 nΩm (4 % - 110 % IACS)
Output data	Resistivity in nΩm
	Conductivity in MS/m or % IACS
Input data	Strip temperature
	Analog input from external source
	Serial com. data from external source

Thickness Gauging - Service

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