Development of a gradation system for measuring surface shine of Galvanized Iron (GI) wires and wire products challenge

Development of a gradation system for measuring surface shine of Galvanized Iron (GI) wires and wire products challenge

We are looking for solutions to categorize GI wires according to its surface shine.

Galvanization is the process of applying a protective zinc coating to steel, to prevent rusting. The most common method of galvanization is hot-dip galvanizing, in which the wires are submerged in a bath of molten hot zinc. We have a continuous hot-dip galvanization setup for producing galvanized (GI) wires, which imparts a shiny appearance to them. Higher shine is an indicator of better corrosion life and results in enhanced customer appeal.

After the manufacturing process, GI wire coils are stacked and stored in the factory for more than a month. Often it is observed that in case of prolonged delay in dispatch from the factory, the material starts losing its shine. Currently, there is no technique to measure and compare the shine. The judgement is solely based on human perception of the shine. There is no method available to determine whether such loss of shine influences the material properties, either. Surface shine is the main criteria for determining the quality of GI wires.

We are looking for a solution to develop a reliable gradation system of the GI wires based on its shine. Based on the shine, appropriate decisions can be made with regards to high, medium or low-quality wires. Such a device will also help in improving and maintaining the shine of GI wires and improving the customer appeal.

Requirements:

  • We are looking for a reliable gradation system of GI wires based on their shine or appearance.
  • The solution should be easy to use, easily interpretable and preferably portable or hand-held.
  • The solution should enable the Quality Assurance team to make decisions regarding the quality of the material.
  • The solution should enable us to determine the shine of wires preferably by a non-contact method and show the results on the device.
  • It is desirable that the device also determines the shine of wires moving at up to 300 m/min.

Constraints:

  • The curved surface of the wires poses difficulty in evaluating the shine.
  • The diameters of the wires range from 1.6 mm to 4.88 mm.
  • The coating thickness of the wires varies from 50 gsm – 300 gsm, i.e. 7 microns to 50 microns.

Awards:- INR 3,00,000

Deadline:- 22-05-2020

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