Traditionally, optical alignment systems (OAS) for finishing block roller guides are adjusted by eye using shadow projection systems on a bench optic. Shadow adjustment methods are subject to human error and require regular calibration of the optical components. Russula has designed a novel guide alignment system based on computer vision. Employing telecentric lenses, high resolution cameras and Russula’s own computer vision algorithms, operators can now adjust the block guides and its mounting bases to perfection, with full digital feedback.
The Russula OAS system includes both tools required to set and align block guides: a bench optic for the setting the roller guides, and a portable optic for aligning the guide saddles to the mill rolls. Guide alignment is simple; first mount the guide on the bench, select the desired profile then turn the adjusting screws according to the instructions on the screen. The portable OAS follows a similar procedure to align the RE guide bases to the roll grooves. Both models are rugged, designed and tested to withstand the harsh working conditions of rolling mills.
The Russula OAS is easy to use. The operator can easily update the profile target database according to any changes in the roll pass design or setup. Navigation can be done from the OAS screens, a laptop or smartphone. Guide and mounting base adjustments take only a matter of minutes. Both the bench and portable models have battery backup, rechargeable batteries that can operate for hours unplugged.
Russula engineers on both sides of the Atlantic have designed, prototyped, manufactured, and commissioned several of the new OAS systems in Europe and the USA. The use of the OAS in steel mills helps reduce downtime and improve the final product quality.