SteelLab: Standard automation for steel samples

Compact design

With the SteelLab, HERZOG offers an optimum solution for sample preparation and OES analysis of steel samples. The SteelLab is characterized by its space-saving design as well as its comprehensive configurability and flexibility. The SteelLab is available as a container laboratory and as a stationary solution without container housing. As a container laboratory, the SteelLab can be accommodated in a standard sea container (6.6 x 2.4 x 2.6 m), which makes transportation to the customer considerably easier and more cost-efficient. It also makes it easier to set up the container laboratory within the plant. The SteelLab is also available with larger container dimensions on request.

Uncomplicated sample registration

As a container laboratory, the SteelLab can be positioned directly at the production site. This makes it possible to analyze the samples taken from the melt without delay. The samples are registered via a registration terminal mounted on the outside of the container and entered via a flap. In most cases, the PrepMaster software establishes an interface to the higher-level Level 2 system in order to automatically receive the sample ID and make it available in a selection list. Alternatively, the sample can also be identified using a barcode scanner or by entering the ident manually.

Self-sufficient unit

As a self-sufficient laboratory, the SteelLab handles all steps from sample preparation and analysis to sample labeling and archiving. The finished analysis results are displayed on the SteelLab and can of course also be forwarded to the control system.

Optimized sample preparation

Within the SteelLab, samples are prepared by the HS-F1000 milling machine, which enables high-precision milling of all common production sample types. The HS-F 1000 also carries out the resource-saving processing of recalibration and control samples. With this type of sample, the cutting of the milling tool is reduced to such an extent that only a minimum of the valuable reference material is removed. In addition, round reference samples can additionally be deburred. The tool changer integrated in the HS-F 1000 enables the selection of the optimum milling tool for the respective sample type.

Simple management of recalibration and control samples

Recalibration and control samples are entered and released via the integrated transfer position. This means that there is no need for the operator to enter the automated system and the ongoing processes will not be interrupted. The system has sufficient magazine capacity to store recalibration and control samples with different diameters. If necessary, the number of magazine locations can be adapted to the specific requirements of each customer. The PrepMaster Entry software offers numerous options for parameterizing the reference measurements. For example, the schedules for measuring control samples can be comfortably configured or the distribution of spark points can be easily defined. 

Partial or global calibration is initiated by the OES instrument itself. The information is forwarded via standard interfaces to the PrepMaster, which controls all further processes. The default procedures generally cover most requirements but can of course be individually customized to meet the needs of each customer. 

Handling of production samples

The production samples to be analyzed are managed, prioritized and, if necessary, buffered in a special magazine by the PrepMaster software. Using the automatic vision system (optional), the SparkPoint module of PrepMaster Entry analyzes the sample surface. This allows the detection of defects and determines the optimum position of the spark points in the preferred sample regions. In addition, even small displacements, and rotations of the sample in the robot hand are detected and automatically corrected when the sample is placed on the spark stand. This increases process reliability and improves analytical accuracy.

Optimized spark stand cleaning

Together with the company SpectroAmetek, we have developed a new unit for spark stand cleaning. This not only cleans the spark electrode, but also the space surrounding the electrode, which leads to a considerable reduction in deposits in the spark chamber. As a result, the already very good operating time of the Spectro Lab S is significantly improved once again. This not only reduces the maintenance effort for the laboratory team, but also increases the availability of the system.

Numerous options

The SteelLab can be supplied with numerous options. These include sample marking systems in the form of label, laser, inkjet, and matrix printers. In addition, a radioactivity measuring device can be supplied, which issues a warning message if a critical threshold value is exceeded. Production samples can be archived in pull-out boxes, but individual solutions are also possible according to customer requirements.

Data analysis using PrepMaster Analytics

PrepMaster Analytics offers numerous benefits in evaluating the analysis results obtained in the SteelLab. For example, PrepMaster Analytics can automatically perform a validation of the analysis results of production samples. It is also possible to automatically determine the measurement uncertainty of the system, monitor the instrument status using various criteria and perform SPC checks on control sample results. The PrepMaster Analytics experiment module can be used, e.g., to perform a plant calibration of an instrument.

In addition, PrepMaster Analytics offers the option of tool condition monitoring (TCM) of the milling machine. This means that wear on the milling cutters, for example, can be detected automatically. Furthermore, the performance, maintenance and error analysis options offered by PrepMaster Analytics supports an intelligent control of the SteelLab.