In precision tube manufacturing, every detail counts – especially the geometry of the strip edge, which is later welded into a tube. With ConScan®, a highly precise real-time measurement and visualization system from hpl-Neugnadenfelder Maschinenfabrik GmbH, strip edge contour can now be monitored directly during machining. This saves time, reduces material scrap, and increases process reliability.
The Strip Edge: The Key to 80 Meters of Precision
In the manufacture of precision tubes, quality often depends on a detail that is barely visible to the naked eye: the geometry of the strip edge. This edge is later welded and must therefore meet the specified angle, the correct height, and a uniform contour. Even the smallest deviations can impair the welding process – and consequently the quality of the finished tube.
The production line at Schoeller Werk GmbH & Co. KG is a prime example of state-of-the-art tube manufacturing. Extending over approximately 80 meters, it processes stainless steel strip from the coil through edge machining and forming to final welding.
Until recently, the strip edge could not be measured and evaluated in real time. Instead, experienced operators had to rely on visual inspection during production and subsequent weld seam evaluation. If a defect was detected at the end of the line, the edge machining settings had to be readjusted – a time- and material-intensive process.
hpl as a Partner and Problem Solver
Focused on developing customized solutions for the specific requirements of tube manufacturing, hpl presented the first ConScan® prototype at a trade fair around six years ago.
At this trade fair, Schoeller became aware of the new online visualization system ConScan®, which scans the strip edge contour in real time and displays it directly to the operator. At the time, this enabled a completely new form of quality control at the very beginning of the tube manufacturing process.
Although the first generation of the system did not yet achieve the measurement accuracy required by Schoeller, it attracted considerable interest.
“We need accuracy in the hundredths range in order to make any meaningful statement at all,” emphasizes Matthias Quetsch, technical manager at Schoeller Werk GmbH & Co. KG.
This marked the beginning of close cooperation between the two companies. Step by step, hpl further developed ConScan®, optimized the measurement technology, increased the resolution, and adapted the system precisely to the requirements of the precision tube manufacturer.
Measurement and Visualization in Real Time
The result is a measurement and visualization system that scans the strip edge using multiple high-resolution sensors and displays the contour simultaneously at the operator panel.
Right at the beginning of the 80-meter production line, operators can verify whether the strip edge contour meets the high-quality requirements for a flawless weld seam and readjust it immediately if necessary.
“Our goal from the very beginning was to develop a system that combines maximum precision with straightforward integration into existing production lines,” explains Günter Veldmann, Sales Representative at hpl-Neugnadenfelder Maschinenfabrik GmbH.
With the latest generation of the system, ConScan® ultimately met Schoeller’s high precision requirements – both in terms of measurement accuracy and real-time visualization of the strip edge contour.
To validate performance under real production conditions, Schoeller conducted a multi-week trial using a test unit directly in the production line.
The trial proved successful: for the first time, operators were able to detect immediately if the edge geometry was out of tolerance and make targeted corrections before deviations became apparent further down the line.
Efficiency Gains in Schoeller’s Tube Production
With the installation of ConScan®, Schoeller expects significant improvements in the start-up phase. Previously, operators had to wait for the first weld seam results before evaluating quality. Today, strip edge geometry can be verified at the very beginning of the line. This enables faster decisions and immediate corrective action, ensuring that deviations are eliminated before they reach the welding stage.
“In the past, we sometimes had to process several meters of strip before we could say with certainty whether the edge was correct,” explains Matthias Quetsch. “Today, we know within seconds – and can respond immediately.”
Start-up times during product changeovers are also expected to decrease significantly. What once required several adjustment cycles can now often be achieved with a single fine-tuning step. This increases material savings, minimizes downtime, and enhances production flexibility.
Another advantage Schoeller expects from ConScan® is the visual display of the strip edge contour on the operator panel, which makes deviations immediately visible – even to less experienced employees. This helps ensure process reliability regardless of the individual operator’s level of experience.
Even minor chipping of the cutting edge, which can negatively affect weld seam quality, can now be identified at an early stage and eliminated by replacing the tool before it impacts production.
Conclusion: An Investment in the Future
With the successful integration at Schoeller, the foundation has been laid for more efficient, flexible, and reliable tube production in the future.
For manufacturers of welded precision tubes, ConScan® offers the opportunity to ensure quality right at the beginning of the production line – long before deviations become visible in the weld seam.
For Schoeller, ConScan® has made a previously invisible factor measurable – paving the way for greater process reliability and shorter response times.
“From a technical point of view, I would recommend the system at any time,” concludes Matthias Quetsch. “And our collaboration with hpl was characterized by openness, inventiveness, and a consistent focus on solutions.”
