Aluminum Industry Services and Products

Compact Universal X-Ray Gauge System

We are pleased to introduce the SenTek 535 Gauging System, a new, compact, economical thickness gauge system based on the STXR-10 X-ray sensor and the SenTek 500 Gauge Electronics Platform.The low cost and economy of the 535 X-ray is a result of the low component count and modular design – the 535 X-ray gauge has the fewest components of any of our X-ray systems. The low component count results in a gauge system with reliability and ease-of-service far beyond its price tag.

The STXR-10 X-ray sensor features a unique air-cooling setup that does not require an external chiller – a big savings in cost and maintenance headaches!

The STXR-10 and the 500 System are the main components of our new 535 modular X-ray gauge.

Additional Features:

-The 535 Universal X-ray gauge is uniquely suited for use on inspection lines, slitters, re-coilers, and crop shear gauges. It can also be used as an entry-level rolling mill gauge. The unique air cooling of the STXR-10 X-ray sensor allows it to operate comfortably in ambient temperatures up to 80 to 90 degrees C.

-The compact size of the 535 sensor components permits a compact, low-profile design of the C-frame and the sensor housing. The 535 can be installed in spaces where many larger gauges do not fit.

Hot Mill Profile Gauge

SenTek’s 1000 System is now available as a multi-zone cross-machine simultaneous profile thickness gauge for aluminum hot mill applications. Available with up to 45 parallel measurement zones, the SenTek 1000 MZP can provide accurate measurement for bending, side-set, leveling, spot cooling, and strip edge management. The SenTek 1000 MZP features fan-beam x-ray sources with 1, 2, or 3 detectors each, depending on the application and desired resolution. Up to 15 X-ray sources can be installed on the same frame.

Built on SenTek’s simple and reliable STXR-10 thickness sensor, the 1000 MZP Gauge is built with fewer components compared to past generations of gauging systems, resulting in lower cost and easy maintenance. SenTek’s Multi-Zone Profile Gauge is built with a forced-air cooled X-ray source mounted in a vibration-proof shock-mount suspension. A unique air-flow vent arrangement together with a forced-air cooling system allows the X-ray source to function comfortably in the Hot Mill environment.

Additional Features:

-In the Multi-Zone Profile gauge application, each X-ray source can be mated to a detector housing featuring one, two, or three X-ray detectors.

-All SenTek 1000 Gauge systems have an optional coil report feature available. For the SenTek 1000 MZP Gauge the standard coil report features a length-based thickness trace for the center-line measurement zone, and a 3-D surface graph for easy review of thickness trends and anomalies. Coil Report files can be archived on the gauge hard disk or on a file server as desired.

-SenTek’s 1000 Gauge System can be equipped with dual monitor outputs, allowing the operator to see gauge measurement and control action at the same time.

Even experienced operators can become distracted when multiple control parameters are presented on different screens and in different formats. SenTek’s gauging system provides a comprehensive Profile Management overview display that allows the operator a detailed insight into all the mill parameters that affect the thickness profile, including bending, skewing, and spot cooling.

Thanks to the flexibility of LabVIEW, custom algorithms for calculating % profile, side set, and many other profile qualification numbers are easily absorbed into the operator information.

Calibration Standards for Use by Our Customers

SenTek provides calibration standards for use by our customers to calibrate and maintain thickness and coat weight measurement systems.

Our engineers and technicians work with each customer to carefully select the materials for each sample set. Sample materials are selected to ensure that each gauge calibration covers the intended range of thickness, coating mass, alloys, and chemical compositions. Samples are cut, cleaned, and processed at the laboratory facility in our Columbus plant. In some cases we will travel to the customer’s plant site and perform our sample and standards laboratory in conjunction with the plant’s QC personnel and QC laboratory, to ensure perfect synchronization in the calibration results between the customer’s gauges and process QC laboratory.

SenTek’s Samples and Standards Laboratory can establish precise thickness through direct contact measurement (micrometer), and for added precision, thickness and coating by weight. At the completion of each Samples and Standards project, a certificate is issued that shows the traceability of the standards and the equipment used.

Beta Thickness Gauge

SenTek’s STB-1 300 mCi beta thickness gauge is a proven design with a track record of long and reliable service in the aluminum industry. Recent improvements include temperature-controlled head heaters and heated air wipes, an added internal check flag for automated gauge checks, vertical air curtain, and a stretch-tension source holder window for added temperature stability during cold start up rolling.

STB-1 Sr-90 Beta Gauge can be mated with either the SenTek 1000 or the SenTek 500 Gauge Electronics Platforms for a complete and competent gauging system.

Why Beta Gauges? Beta gauges are insensitive to changes in the alloy chemistry composition of the material being measured.

Our beta sensors can be combined with our X-ray sensors in a dual-gauge configuration for increased accuracy and flexibility.

Beta Thickness Gauge

SenTek’s STB-2 400 mCi beta thickness gauge is a proven design with a track record of long and reliable service in the aluminum industry. Recent improvements include temperature-controlled head heaters and heated air wipes, an added internal check flag for automated gauge checks, vertical air curtain, and a stretch-tension source holder window for added temperature stability during cold start up rolling.

SenTek’s STB-2 adds additional signal strength for 25% lower noise and faster measurement compared to our STB-1 gauge.

STB-2 Sr-90 Beta Gauge can be mated with either the SenTek 1000 or the SenTek 500 Gauge Electronics Platforms for a complete and competent gauging system.

Why Beta Gauges? Beta gauges are insensitive to changes in the alloy chemistry composition of the material being measured.

Our beta sensors can be combined with our X-ray sensors in a dual-gauge configuration for increased accuracy and flexibility.

Beta Light Gauge

SenTek’s STB-3 beta thickness gauge is a proven design with a track record of long and reliable service in the aluminum industry. Recent improvements include temperature-controlled head heaters and heated air wipes, an added internal check flag for automated gauge checks, vertical air curtain, and a stretch-tension source holder window for added temperature stability during cold start up rolling.

The added internal check sample can be used to re-tune a standard beta gauge to operate successfully at a thinner, lighter gauge (down to 0.002 inch / 0.05 mm).

Why Beta Gauges? Beta gauges are insensitive to changes in the alloy chemistry composition of the material being measured.

Our beta sensors can be combined with our X-ray sensors in a dual-gauge configuration for increased accuracy and flexibility.

Gamma Thickness Gauge

For the latest design of the gamma gauge system, SenTek listened to shift electricians, millwrights, and control engineers to provide gamma gauges that offer easier service, faster measurement, and lower noise than ever before.

The STG-1 gamma thickness gauge is a low-intensity thickness gauge primarily for inspection gauges, slitters, crop shear stations etc. Built with robust components, its simple design features the lowest component count of any gauge device that we make. The simplicity and robust design has resulted in a service record of nearly ten years MTBF.

The STG-1 gamma thickness gauge can be mated with either the SenTek 1000 or the SenTek 500 Gauge Electronics Platforms for a complete and competent gauging system.

Why Gamma Gauges? Gamma gauges are insensitive to changes in the alloy chemistry composition of the material being measured. They are also robust and simple, since they do not require any tuning components.

SenTek’s gauge device design contains a built-in automatic check sample that allows repeated and precise tracking of gauge accuracy and performance. Automate the gauge check.

The simple construction of the STG gamma sensors makes it possible to construct very narrow and low-profile thickness gauges for tight spots.

High-Intensity Gamma Thickness Gauge

For the latest design of the gamma gauge system, SenTek listened to shift electricians, millwrights, and control engineers to provide gamma gauges that offer easier service, faster measurement, and lower noise than ever before.

The STG-2 high-intensity gamma gauge has all the same great features of the STG-1 gauge, but adds multiple signal strength for much lower noise and faster measurement. This gauge is primarily intended for aluminum hot rolling applications as well as steel and stainless steel cold rolling.

The STG-2 gamma thickness gauge can be mated with either the SenTek 1000 or the SenTek 500 Gauge Electronics Platforms for a complete and competent gauging system.

Why Gamma Gauges? Gamma gauges are insensitive to changes in the alloy chemistry composition of the material being measured. They are also robust and simple, since they do not require any tuning components.

SenTek’s gauge device design contains a built-in automatic check sample that allows repeated and precise tracking of gauge accuracy and performance. Automate the gauge check.

The simple construction of the STG gamma sensors makes it possible to construct very narrow and low-profile thickness gauges for tight spots.

Foil X-Ray Thickness Gauge

The STXR-1 X-ray is a low-kV soft X-ray sensor for aluminum foil, food packaging, and light-gauge flat sheet applications. It is a compact, modular sensor with fewer components than many previous generations of light-gauge X-rays. It is mechanically identical to our STXR-10 Universal Light Gauge (for heavier metals) – It differs from the STXR-10 only in its tuning and application.

The STXR-1 foil thickness gauge can be mated with either the SenTek SenTek 1000 or the SenTek 500 Gauge Electronics Platforms for a complete and competent gauging system.

Compact X-ray Source: Our STXR-1 X-ray source assembly is a compact assembly with a unique air vent/air flow arrangement. With low-volume forced-air cooling, the STXR-1 will operate comfortably in ambient temperatures of 80 to 90 degrees C and beyond. For new gauge installations, the very small size of the STXR-1 permits it to be installed in low-profile, narrow housings and C-frames.

Thermal Stability and Conditioning:  All of SenTek’s gauge sensors, including the STXR-1 and STXR-10, can be equipped with external, hardened thermistors for air gap temperature monitoring. They can also be equipped with heated air wipes and air columns for even greater thermal stability.

Universal Light Gauge X-Ray

The STXR-10 X-ray is a new X-ray sensor for a wide variety of aluminum sheet products as well as light-gauge steel, stainless, copper, and brass. STXR-10 is a compact and light-weight modular sensor. It is mechanically identical to our STXR-1 foil gauge – It differs from the STXR-1 only in its tuning and application.

The STXR-10 thickness gauge can be mated with either the SenTek SenTek 1000 or the SenTek 500 Gauge Electronics Platforms for a complete and competent gauging system.

The STXR-10 and the 500 system are the main components of our new 535 modular X-ray gauge.

Compact X-ray Source: Our STXR-10 X-ray source assembly is a compact assembly with a unique air vent/air flow arrangement. With low-volume forced-air cooling, the STXR-10 will operate comfortably in ambient temperatures of 80 to 90 degrees C and beyond.

Isotope-to-X-ray conversion: The very small size of the STXR-10 sensor components makes it possible to fit the entire X-ray assembly in the source housing of an older isotope gauge. This permits us to convert older isotope gauges to modern high-speed X-ray gauges without any mechanical changes to the process line.

For new gauge installations, the very small size of the STXR-10 permits it to be installed in low-profile, narrow housings and C-frames.

Thermal Stability and Conditioning:  All of SenTek’s gauge sensors, including the STXR-10, can be equipped with external, hardened thermistors for air gap temperature monitoring. They can also be equipped with heated air wipes and air columns for even greater thermal stability.

Light Aluminum X-Ray Gauge

SenTek’s STXR-2 X-ray gauge is primarily used in the aluminum industry as a high-speed, low-noise control gauge for light-gauge aluminum. It can also be used as a high-end monitoring and inspection gauge to find fast, repetitive thickness variations in the strip that ordinary gauges cannot see, such as third-octave mill chatter and roll marks.

The STXR-2 thickness gauge can be mated with either the SenTek 1000 or the SenTek 500 Gauge Electronics Platforms for a complete and competent gauging system.

X-ray Alloy Chemistry Compensation: SenTek offers an advanced alloy chemistry and structure factor model for our X-ray gauges to enhance the gauge accuracy.

Gauge Signal Spectrum Analyzer: As an optional feature, SenTek offers a built-in Spectrum Analyzer with our gauge software for our high-speed X-ray gauges to make it easier for mill operators and engineers to find and document repetitive thickness variations.

The Spectrum Analyzer can be further combined with a vibration Accelerometer to sort out vibration-induced gauge errors in the rolling mill.

Additional Features:

-SenTek’s X-ray sensors can be built in a narrow-set, low-profile version that saves space and fits into tighter spaces than ordinary gauges.

-Our X-ray sensors can be combined with isotope sensors in a dual-gauge configuration for increased accuracy and flexibility.

Light Aluminum X-Ray Gauge

SenTek’s STXR-3 X-ray gauge is primarily used in the aluminum industry as a high-speed, low-noise control gauge for light-gauge aluminum. It can also be used as a high-end monitoring and inspection gauge to find fast, repetitive thickness variations in the strip that ordinary gauges cannot see, such as third-octave mill chatter and roll marks.

The STXR-3 thickness gauge can be mated with either the SenTek 1000 or the SenTek 500 Gauge Electronics Platforms for a complete and competent gauging system.

X-ray Alloy Chemistry Compensation: SenTek offers an advanced alloy chemistry and structure factor model for our X-ray gauges to enhance the gauge accuracy.

Gauge Signal Spectrum Analyzer: As an optional feature, SenTek offers a built-in Spectrum Analyzer with our gauge software for our high-speed X-ray gauges to make it easier for mill operators and engineers to find and document repetitive thickness variations.

The Spectrum Analyzer can be further combined with a vibration Accelerometer to sort out vibration-induced gauge errors in the rolling mill.

Additional Features:

Compact Universal X-Ray Gauge System

The STXR-5 X-ray thickness gauge is used for heavier gauge applications such as plate mills and hot mills. It can be tuned for multiple thickness ranges and features an auto-set function for each thickness range.

The STXR-5 heavy X-ray gauge is available with the SenTek 1000 Gauge Electronics Platforms for a complete and competent gauging system.

High Temperature Gauge Environment: In the hot rolling environment, our C-frames are equipped with high-temperature seals and windows, water cooling and forced air continuous venting to ensure a long life, stable measurement, and safe operation. The low surface area design and high-reflectivity sensor windows minimizes heat pickup from the process.

Pin-point diagnostics, visual parts identification, and electronic troubleshooting are several features of the SenTek 1000 that makes our gauging systems easy to service even in difficult and hazardous locations.

Additional Features:

-The STXR-5 heavy X-ray gauge features our SenTek 9001 X-ray source package. This is a light-weight compact monoblock hybrid-tube design that is significantly smaller, lighter, and less expensive than the X-ray sources of past generation thickness gauges.