Minimize Lab Effort: Lab-Automation for OES, XRF and XRD Analysis

QCS CONTAINER LABORATORY CL100

The QCS CONTAINER LABORATORY CL100 is the alternative to QCS INDIVIDUAL CENTRAL LABORATORY and can be installed at a mobile location. The CL100 is a fully automated quality control system for the steel, stainless steel, cast iron, pig iron and non-ferrous metal samples such as aluminum and copper. The automated process includes sample identification and transport, sample preparation and material analysis. Sample feeding, robot control and status monitoring are performed via a computerized control system. To ensure standardized quality assurance, the interior is air-conditioned to a temperature of 20 °C. The entire cycle takes approx. 2 minutes until the analysis result is available. Up to 500 samples per day thus pass through the quality assurance on average (depending on material).
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Technical description

The sample is registered on the outside at a touch control terminal via the HMI software and moved into the container via the adjacent flap on a transport carriage. The laboratory is then sealed and the robot takes over all further steps.
The programmed robot is the central component of the container and transports the sample step by step from the slide of the track system to the sample milling machine for image processing to the OES analyzer and from there to the label printer and into the sample station for intermediate storage of the sample materials.
The sample camera system checks the sample for cracks and blowholes as well as the height of the sample. The temperature of the sample is then measured to determine whether it must first be cooled in the sample cooler or can be milled. In addition, the sample camera system identifies suitable locations for metal analysis on the blank milled surface of the sample and passes this information to the robot via our software.
The sample is fed to the OES analyzer and placed precisely on the spark stand, sparked and the data is transferred to your software via an interface. If the results of at least two measurements agree within the permissible tolerances, the OES-analysis is complete.
Each sample receives a label with time, origin and identification number is placed in the sample station and can be assigned at any time. There is space for 30 samples here. If the sample station is filled to the maximum, the robot sorts out the oldest sample. The entire cycle can be viewed and controlled via the QCS SAMCOS software.

Components overview

HARDWARE:

  • QCS INPUT DESIGN WITH FEED CARRIAGE
  • TOUCH-OPERATING TERMINAL
  • ROBOT(ABB OR KAWASAKI)
  • QCS SAMPLE COOLER PK100
  • QCS SAMPLE MILLING MACHINE PF100
  • SAMPLE CMAERA SYSTEM
  • STATIONARY OES-ANALYZER
  • QCS SAMPLE STATION PS100
  • QCS LABEL PRINTER LD100
  • QCS CONTROL CABINET
  • QCS WATER TANK + PUMP AND ARGON PURIFICATION

SOFTWARE:

  • QCS HMI (HUMAN-MACHINE INTERFACE)
  • QCS SAMCOS (SAMPLE CONTROL SYSTEM)
  • QCS PLC (PROGRAMMABLE LOGIC CONTROLLER)

QCS INDIVIDUAL CENTRAL LABORATORY

The QCS INDIVIDUAL CENTRAL LABORATORY can be individually designed and programmed for each of our industrial application (STEEL, CEMENT, MINING, NON-FERROUS, CHEMICAL, RECYCLING). Unlike the QCS CONTAINER LABORATORY CL100 the central laboratory covers more area, which allows to integrate several milling machines with different parameters and different analysis methods (e.g. OES, XRF/XRD, CNS or LIBS). In addition, it offers the advantage of centralization (e.g., only one software license is needed). On the other hand, the cycle to the analysis result takes longer than in a container, since it cannot be installed directly at the production site (e.g., at the melt pot). The following example is a fully automated central laboratory including sampling, sample transport, sample preparation and sample analysis of steel or nonferrous metals. Sample feeding, robot control and status monitoring are carried out via a higher-level computer-controlled control system. The cycle time depends on the scope of sample preparation.

Technical description

The sample is taken by our sampling system
The material is transported by airtube system to the central laboratory at maximum speed (up to 40 m/s)
The sample is automatically unpacked by pneumatic lid opener
The robot circuit takes over and transports the sample according to individually programmed step chain
Depending on the sample material, the sample is now prepared for analysis For solid specimens: The specimen is cooled by specimen cooler and then milled or ground by our specimen milling machine For powdered samples (e.g. slag): The sample is crushed by our jaw crusher and then formed by our pulverizing and pelletizing machines
The sample is analyzed with a stationary OES, XRF/XRD or LIBS-analyzer (depending on your choice)
The entire cycle can be viewed and controlled via the QCS SAMCOS software.

Components overview

HARDWARE:

  • QCS AUTOMATIC SENDING- AND RECEIVING STATION
  • QCS AIRTUBE SYSTEM
  • QCS AIRTUBE DIVERTER
  • QCS LABORATORY STATION
  • TOUCH-OPERATING TERMINAL
  • ROBOT (ABB OR KAWASAKI)
  • QCS PNEUMATIC LID OPENER DA100 (FOR SAMPLE CAPSULE)
  • QCS SAMPLE COOLER PK100
  • QCS SAMPLE MILLING MACHINE PF100
  • QCS SAFETY FENCE
  • SAMPLE CAMERA SYSTEM
  • QCS QCS SAFETY FENCE
  • STATIONARY OES-ANALYZER (OR XRF/XRD, LIBS, CNS)
  • QCS SAMPLE STATION PS100
  • QCS LABEL PRINTER LD100
  • QCS CONTROL CABINET

SOFTWARE:

  • QCS HMI (HUMAN-MACHINE INTERFACE)
  • QCS SAMCOS (SAMPLE CONTROL SYSTEM)
  • QCS PLC (PROGRAMMABLE LOGIC CONTROLLER)
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PMI-OES ROBOTIC: Automated Positive Material Identification

Our PMI-OES ROBOTIC takes over the analysis of elements for finished steel, iron and non-metal bars or tubes. Unlike the conventional process, which is carried out manually by personnel, our exchange tester provides reliable measurement results 24/7 in multi-shift operation, due to dimensionally accurate and targeted programming as well as positioning of servo motors. The measurement result including preparation for a measurement is available within 22 seconds. In case of significant deviations, the cycle is repeated up to 3 times (depending on the customer’s requirements). The system is designed in such a way that it is possible to perform up to 5 measurements in one run and to compare them with the previously calibrated target values. In addition, it is possible to perform quality control directly during production. It is possible to test either on the rounded side of the bar (from above) or on the flat face side (from the side).

Technical description

Before the machine is set to automatic, a recalibration takes place in order to store the set values of elements as an adjustment in the system. This is usually done by 3 measurements at different points so that an average value is used as a reference.
Then the finished rods/tubes are gradually pushed to our developed clamping device. Applied sensors detect that the bar/tube is in position so that the cylinder is triggered and holds the material up to a diameter of 120mm in position during the entire process.
To obtain more representative analysis results, the surface of the rod is abraded by our integrated grinding unit
Now the first OES-analysis takes place. The result is immediately transferred to the customer software
In case of significant deviations, the process is repeated up to 3 times, but can also be extended up to 5 times. The total cycle time is extended accordingly.
If there are still deviations, it is possible to select on the touch control terminal whether the pipe is to be approved or rejected.
A cleaning unit developed by us automatically cleans the electrode of the spark spectrometer at an individually adjustable frequency, ensuring reliable measurement results even over several hours in automatic mode.

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