HQ 5
Non-Destructive Hardness Measurement
High quality rolls are the heart of every mill. Their hardness determines service life, process reliability and end product quality. But the current practice of hardness testing has serious disadvantages: it is time-consuming, leaves marks on the surfaces and is carried out on a random basis. In addition, unnecessary material loss due to excessive roll grinding increases the cost of restoring the homogeneity of hardness across the barrel.
To optimize this process, Herkules has collaborated with QASS, a specialist in process optimization, sensor technology, component monitoring, and quality assurance, to develop the unique and revolutionary HQ 5 hardness testing measurement system.
It uses a ferrite antenna to measure the hardness of the roll core contactless (non- destructively), on the fly, fully automatic and in real time, replacing error-prone manual measurements with comprehensive and precise results – for maximum quality, efficiency, and cost-effectiveness in the roll shop.
100% Surface Coverage Instead of Spot Checks
- Local hardness variations are reliably detected and visualized in 3D
Non-Destructive
- No indentations on the roll surface
- Measuring on the fly: Rolls remain fully operational – immediately and without reworking
- Fully automatic and efficient
No Personnel Expenses for Performing Manual Measurements
- Increased process and operational reliability
- Early detection of deviations
Extended Roll Lifetime
- Minimal grinding required; fully automated regrinding to restore original hardness
100% Integration into the PGC 10 Roll Grinder Control System
- Machine operation, measurement, data documentation, and analysis all in one system
- Real-time data processing
HQ 5 Technology
The microstructure of the roll surface consists of millions of tiny grains, each acting like a miniature magnet (micromagnet). Initially, these micromagnets are randomly aligned, cancel-ling each other out magnetically.
The HQ 5 generates an alternating magnetic field that causes the micromagnets in the roll surface to align in a common direction. The harder the surface, the more resistance it offers to this reorientation. This behavior provides valuable insights into the material’s mechanical properties. A ferrite antenna positioned just above the roll surface measures the finest magnetic changes with high precision. This provides accurate information about the microstructure and magnetic behavior of the material — all in real time and without damaging the roll.
