INITIAL SITUATION
In heavy industry, especially in steel manufacturing, the surface condition of rolls is directly linked to the quality of the produced material.
Rolls play a crucial role in shaping, transporting, and finishing steel products. Surface defects on rolls can lead to serious issues such as product flaws, increased wear, production downtime, and costly maintenance interventions.
At an Indian steel manufacturer, it became necessary to implement an efficient, precise, and fully automated surface inspection system based on the non-contact laser triangulation measurement method.
Rolls are exposed to extreme mechanical stress, thermal fluctuations, and abrasive environments. Even minor surface anomalies such as cracks, dents, or wear zones as small as 0.01 mm can transfer to the steel end product, resulting in aesthetic defects, structural weaknesses, or deviations from technical specifications (according to ISO 8503 standards for surface quality).
Furthermore, defective rolls can accelerate wear on adjacent components, leading to a cascade of maintenance costs. Industrial studies have shown that undetected surface defects can reduce roll lifespan by up to 30% and cause unexpected production stoppages (source).
Therefore, reliable, timely, and precise inspection is critical for optimizing productivity, maintaining product quality, and ensuring workplace safety.
Conventional inspection methods relying on visual or manual measurements are time-consuming, operator-dependent, and insufficiently sensitive to detect microdefects. Given the narrow time windows available during scheduled maintenance shutdowns, a faster and more objective solution was required.
For the automatic inspection of roll surfaces, a state-of-the-art laser triangulation system was introduced. Using a high-precision 3D scanner, the system captures detailed surface topographies by scanning the roll strip by strip.
A cutting-edge 3D laser sensor that enables scanning at micrometer-level resolution.
Intelligent software for controlling scan parameters and automating the inspection process.
An optimized data acquisition pipeline that delivers a high-resolution point cloud for defect analysis.
The implementation of this system provided significant benefits to our customer:
Automation and Speed: The entire roll surface is inspected rapidly and without human intervention, greatly reducing inspection times.
High Objectivity and Reproducibility: Uniform inspection criteria ensure consistent results and eliminate human subjectivity.
Outstanding Detection Capability: Microdefects smaller than 10 micrometers are reliably detected, helping to prevent product flaws and roll degradation.
Preventive Maintenance through Comprehensive Data: Complete 3D models of roll surfaces are available for current defect assessment and future trend analysis.
Enhanced Reporting and Traceability: Detailed defect logs, screenshots, and data archives provide reliable documentation and support ISO 9001 quality management requirements.
With QuellTech’s new laser system, the plant can now ensure that roll conditions are systematically and continuously monitored and maintained at optimal levels. This guarantees consistent product quality, reduces scrap rates, and improves operational efficiency. Additionally, it extends equipment lifetime and strengthens overall customer satisfaction.
The success of this project demonstrates how effectively the combination of cutting-edge 3D scanning technology and intelligent automation can meet the demanding standards of modern steel production.
We are happy to help you with that!
Stefan Ringwald
Technical Consultant
We would like to help you to evaluate your specific measurement task.
With an initial free test measurement of your application, we can give an early assessment of the feasibility. Do not hesitate to contact us for more information or to make an appointment for a consultation. Please talk to us!
Your technically competent contact, Stefan Ringwald, will be happy to help you.
Our aim is to fully understand your specific technical requirements for your current measurement task.
Thanks to many years of experience with complex tasks in the field of 3D laser measurement, you will receive well-founded solution proposals from us.
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Hinweis für Deutsche Unternehmen:
Für Investitionen in Ausrüstungen gilt seit Juli 2025 eine degressive Sonderabschreibung von bis zu 30% p.a. – befristet bis Ende 2027.
Je früher die Anschaffung erfolgt, desto länger kann dieser Vorteil genutzt werden.
(Dies ist keine Steuerberatung, bitte wenden Sie sich für Details an Ihre Steuerberatung.)
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