Encoders | Proximities | Non-Contact Temperature Measurement

Evolved from a component distributor to a knowledge base engineering enterprise by actively listening to the customers to deliver value

40 years of excellence in serving the Metal & Mining industry

Explore

Robust. High Performance. Accurate

High performance sensors for harsh operating environments

Explore

Fire safety in coke wharf

Sensor and control technology solutions that ensure safety,
operational efficiencies and reduce downtime

Explore

Next Generation Sensors

Smart sensor solutions for the needs of industry 4.0

Explore

Our Products

Explore Our Solutions

Rolls,Of,Steel,Sheet,,Cold,Rolled,Steel,Coils

Overspeed switch EGSH 41 ensures safely limited speed in the mill stand

CRM, Steel & Rolling Mills

Overspeed switch EGSH 41 ensures safely limited speed in the mill stand

CRM, Steel & Rolling Mills

For precise speed control in rolling mills the main drives of the roll stands and the coilers need to be equipped with an encoder. In addition, it is often necessary to provide increased protection for personnel during special operating modes, such as: For this application Johannes Hübner Giessen has been working with Motor OEMs for many decades to provide complete solution ie. Electrical and mechanical components. Home Case Studies Overspeed switch EGSH 41 ensures safely limited speed in the mill stand Overspeed switch EGSH 41 ensures safely limited speed in the mill stand Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Safeguards personnel carrying out necessary work in the danger zone Switching points set without intervening in the PLC programming Safety certified encoder simplifies risk assessment Complete solution including safety mechanical parts and installation service Safety certified system solution consisting of heavy duty encoders and tailor-made mechanical attachments. Challenges In addition to sensing speeds for motor control and protection it is also necessary to implement the safety function SLS (Safely-Limited Speed) for the main drive and for each coiler. The purpose behind this measure is to safeguard personnel in the danger zone as they carry out necessary inspection and maintenance work on machinery. The conceptual solution designed to implement SLS should also take into consideration reliable mechanical assembly. Solution The first step was to document the requirements and the installation conditions at the customer’s site before drawing up an overarching concept for the different points of installation. System solutions consisting of safety-certified, hollow-shaft type overspeed switches EGSH 41 (SIL 2 / PL d) as well as attachments calculated for safety and guaranteed fault exclusion are at the core of our customized solutions. An additional encoder with incremental output for motor control and a speed switching output for motor protection were integrated in the system solution as required. Hübner specialists installed all of the system components and carried out control measurements to verify the accuracy of the installed equipment and documented the results. Turnkey encoder modernization by engineering support package with site measuring, construction, mounting and commissioning support. Products and Accessories Heavy duty programmable overspeed switch Speed feedback for main drives Adapter Shaft Tether 1:1 Replacement for Mechanical Cam Limit Switch Couplings Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills – Roughing Mills View All

Replacing mechanical cam limit switches on cranes without PLC

Ports and Cranes

Replacing mechanical cam limit switches on cranes without PLC

Ports and Cranes

The ERC 40 Series of electronic position switches from Johannes Hubner Giessen are the ideal solution for heavy-duty applications demanding the highest level of precision, user friendliness and reliability. These devices make it possible to monitor both position and limit switching point across the complete position range with utmost precision. The ERC 40 Series is reliable, comfortable, flexible and safe. Home Case Studies Replacing mechanical cam limit switches on cranes without PLC Replacing mechanical cam limit switches on cranes without PLC Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Position monitoring – also without PLC Replacement for discontinued cam limit switches Higher positioning accuracy Suitable for 1:1 replacement Before: Mechanical cam limit switch. Challenges Some mechanical cam limit switches deployed in cranes or in conjunction with an obsolete PLC have either been discontinued or the devices cannot be replaced for other reasons. In that case a solution is required that updates the position switches on the crane to a state-of-the-art technology – without extra construction effort. After: The electronic position switch ERC 40 from Hübner Giessen as a 1:1 replacement solution. Solution With the electronic position switch ERC 40 from Hübner Giessen the user is now able to program the high precison switching points via software. The programming is easy and quick. At the same time, the values remain permanently in the system and cannot be affected by shock and vibration. Other advantages are: Real switches up to 230 V and 0.5 A – existing cables can be kept most of the time Use the latest technology without converting to a (new) PLC at the same time The ERC 40 offers a suitable replacement system for many cranes and installation situations. This enables more flexibility, higher accuracy and less spare parts. Products and Accessories 1:1 Replacement for Mechanical Cam Limit Switch Couplings Adapter Shaft Heavy duty programmable overspeed switch Speed feedback for main drives Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills – Roughing Mills View All

Reliable roll detection in aggressive environment

Steel & Rolling Mills

Reliable roll detection in aggressive environment

Steel & Rolling Mills

High demands are placed on the sensor since rolling emulsions are used for surface finishing. The environment is of very high ambient temperatures. PTFE does not allow water or chemical solvents to stick on its surface and has a high melting point of 423⁰ C. Both F/HF 2/3/4/W constructs with a wide sensing range and IP68 class protection. AC or DC supply input combinations of transistor or relay outputs available. Home Case Studies Reliable Roll Detection in Aggressive Environment Reliable Roll Detection in Aggressive Environment Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Field-proven proximity performance in aggressive emulsions conditions in CRM mill Reliable detection of lock /unlock position of the back-up, work and intermediate rolls Increase mill availability as proximity are maintenance-free reducing downtime Resistant against emulsions , lubricants, coolants, water jets, dust and dirt Chemical solvents or water stuck on the surface, affecting output and efficiency. Challenges Frequent proximity failures leading massive production downtime. With grease accumulation, the standard 15mm sensing distance was not sufficient after 3months High ambient temperatures inside the mill housing combined with aggressive emulsions Normal PVC cable cracking after 3-months inside mill housing. The PTFE housing is resistant to greases, oils and acids Field proven Performance End-User: PLTCM / reversing cold rolling mills at Tata, JSW, SAIL,AMNS. OEM: Primetals preferred choice for upgrade of CRM-1 at JSW Bellary was Proxitron Solution PTFE single piece housing is resistant to greases, oils and acids, e.g. in cold rolling operations. 19-25mm large sensing distance available 100 |120 °C high temperature electronics 260°C cable excellent resistance to acids, varnishes, oils, hydraulic fluids etc., hardly inflammable, low water absorption, weather and ozone resistant. Special connection cable to prevent emulsion entering the housing/ electronics. Universal supply voltage (20-240VAC/DC) available with combinations of transistor or relay outputs. Products and Accessories Cold rolling mill proximity Key Specifications Sn: 19-35 mm IP: IP 68/69K Temp: 70|100|120 °C Supply voltage: 20-260 V AC/DC Cable length: 2,5,10,15,20 m # wires: 2-wire, 3-wire Housing (Ǿ): M32, M35 Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

View,Of,Inside,Of,Steel,Reheating,Furnace,With,Gas,Flame

Prevent slab pile up by view inside the RHF

Hot Rolling Mill, Steel & Rolling Mills

Prevent slab pile up by view inside the RHF

Hot Rolling Mill, Steel & Rolling Mills

Home Case Studies Prevent slab pile up by view inside the RHF Prevent slab pile up by view inside the RHF Operator to get inside view of the walking beam furnace. Prevent any slab pile-up leading to loss in production. Visual camera to operate in high ambient temperature to withstand upto 2200 °C. Rugged camera in a stainless housing and complete electronics for safe monitoring of retraction / shutter device to actuate when water supply is accidentally switched off. Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Profile temperature measurement to ensure quality of rolling and prevent cobble Compare edges temperature and centre to adjust the spray headers/ furnace Measure drop out temperature at exit of furnace even in presence of high oxidation Measure the bottom profile temperature to prevent hook-up / cobble 3Lakhs temperature points scanned Challenges Operator to get inside view of the walking beam furnace Prevent any slab pile-up leading to loss in production Visual camera to operate in high ambient temperature to withstand upto 2200 °C Solution 3 options for housing Rugged camera in a stainless housing and complete electronics for safe monitoring of retraction / shutter device to actuate when water supply is accidentally switched off. Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Manual rod to check the camber measurement Case Studies Other Solutions in Reheating Furnace Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Slab Pusher Position Feedback

Hot Rolling Mill, Steel & Rolling Mills

Slab Pusher Position Feedback

Hot Rolling Mill, Steel & Rolling Mills

Rope got damaged and blocked the inlet nozzle. The plastic cover melted leading to failure of spring cartridge. The dust particle entered inside the housing. Heavy duty rope length transmitter was designed for these harsh environment conditions:-higher force rope thicker rope of 2mm with PA coating instead of standard 0.8mm / 1.35mm. Home Case Studies Slab Pusher Position Feedback Slab Pusher Position Feedback Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Heavy Duty rope length transmitter for heavy duty environment Higher force Thicker rope (2mm) with PA coating Easy cleaning as it is open design Simple and robust mechanism Challenges Rope got damaged and blocked the inlet nozzle. The plastic cover melted leading to failure of spring cartridge The dust particle entered inside the housing. Solution Heavy duty rope length transmitter was designed for these harsh environment conditions:- Higher force rope Thicker rope of 2mm with PA coating instead of standard 0.8mm / 1.35mm Rope can be easily changed by the customer themselves Open designed with grooves allowed dust not getting collected inside the drum Products and Accessories Heavy duty Rope Length Transmitter Case Studies Other Solutions in Hot Strip Mill Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Transfer Car Detection using Proximity

Steel & Rolling Mills, Steel Making

Compact IR thermal imaging camera was installed to provide a temperature map of the bottom shell. The cameral scans the full bottom of the shell giving options to define multiple areas /ROI to get 4-20mA output. Software automatically finds hot spots enable timely preventative maintenance. Home Case Studies Special looper encoders withstand the most extreme operating conditions in hot roll stands Transfer Car Detection using Proximity Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Process reliability with proximity Safe supply and discharge of gas Assurance of correct electrode position Proximity installed in steel melt shop Challenges Continuous and reliable management of high temperature is required. Earlier proximity was sensitive to magnetic field and failure in high temperature. Solution Color detecting sensors support positioning of electrodes in electric arc furnace. Proximity is insensitive to magnetic fields. Specifications Sn: 140 mm IP 67 Temp: -25 to +70 °C Supply voltage: 20-260 V AC/DC Cable length: 2,5,10,15,20 m Cable MOC: Silicone cable No. of wires: 3-wire Housing (Ǿ): 110x110x43 Cable conduit protection available (Pg X) Proximity Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other applications in Steel Making Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Temperature Monitoring during Tablet Coating process

Pharmaceutical

Temperature Monitoring during Tablet Coating process

Pharmaceutical

Non contact infra red pyrometer, with cable and sensor head is used for temperature monitoring during the process of tablet coating. It solves the serious problem of overheating, blistering and cratering. The rugged optics allows it to operate it at very high ambient temperature without cooling, with accurate temperature control. Reliable coats and minimum injections are produced as the output. Home Case Studies Temperature Monitoring during Tablet Coating process Temperature Monitoring during Tablet Coating process Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Continuous temperature measurement during the table and capsules coating process resulted in reliable coats and minimum rejections. Sensor output was used as a feedback signal to the air supply for air and temperature control Improved operational efficiency with reduced risks of defects during the tablet coating process Highly accurate and precise temperature control during the coating process Increases process efficiency and consequent production quality, yield and speed Challenges Overheating during the tablet coating process can cause various challenges such as blistering, cratering, pitting, blushing, sticking and picking. High temperature can cause gases to be trapped under the film during the spraying process or at the end of the coating run. Other defects such as cratering may appear exposing the surface of the tablet. High coating temperatures can also cause white specks or haziness to appear on the film. Sometimes pits may occur in the tablet core without a noticeable defect on the on the coating. Tablets may stick to each other and to pan walls. Solution Compact series, contactless IR pyrometer with electronics inside the cable and M12 construct sensor head is ideally suited for this application. The sensor has an object temperature detection range of -50⁰C to 1030⁰ C and offers a fast response of 150ms. With a rugged coated silicon optics it can operate at high ambient temperature of 180⁰C without cooling. It also offers a LED alarm indication, analog (0-5/10V , 4020 mA) with simultaneous alarm outputs Easy programming via smartphone or windows software Products and Accessories Pyrometer Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Next Gen Microscopic Optics for Thermography

R&D

Next Gen Microscopic Optics for Thermography

R&D

Fundamentally improve the operating reliability and positioning accuracy of the ladle crane hoist used in steel production. Installation of the modular universal encoder system U-ONE, which offers the following special characteristics • Basic unit mounted directly at the hoist drum by using a double joint coupling on a tailor-made base plate construction • Signal transmission via fiber optic cable prevents EMC problems Home Case Studies Next Generation Infrared Camera for ultra high resolution imaging of electronic circuit boards Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Current Solution with 0.6x magnification Next Generation Advanced Optics with 2.4x magnification Solution Benefits Combination of multiple optical lens resulting in highest ever magnification level Extreme high resolution to detect over heating on very small components Specifications FOV : 3.5 mm x 4.5 mm Temperature range: -20 °C to 900 °C (optional up to 1 500 °C) Spectral range: 8 to 14 µm Frame rate: up to 125 Hz Products and Accessories Thermal Imaging Camera Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in R&D Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Russia,,Lipetsk,,Novolipetsk,Steel,,Rolling,Mill,2000,,Output,Stands

Special looper encoders withstand the most extreme operating conditions in hot roll stands

Steel & Rolling Mills, Steel Making

Special looper encoders withstand the most extreme operating conditions in hot roll stands

Steel & Rolling Mills, Steel Making

Compact IR thermal imaging camera was installed to provide a temperature map of the bottom shell. The cameral scans the full bottom of the shell giving options to define multiple areas /ROI to get 4-20mA output. Software automatically finds hot spots enable timely preventative maintenance. Home Case Studies Special looper encoders withstand the most extreme operating conditions in hot roll stands Special looper encoders withstand the most extreme operating conditions in hot roll stands Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Subject to high loads from shock, temperature and cooling emulsions Heavy-duty ball bearings with special lubrication Increased lifetime Reduced downtime Loopers in hot rolling mills are working under extremely rough conditions. Challenges Loopers are normally used to control the tension of the metal strip between roll stands. The rotational angle of the looper is measured by a feedback encoder that is exposed to special demands. The setting angle up to only about 45° results in a partial load on the encoder bearings in conjunction with insufficient bearing lubrication. The encoder is subject to high levels of shock and temperature loads as well as oil / cooling emulsions / water at the place of installation. Formerly used standard encoders have not reached the required lifetime. Looper encoder with heavy-duty ball bearings and special lubrication for long lifetime. Solution For this application Johannes Hübner Giessen developed a special looper encoder, which boasts a considerably longer lifetime thanks to especially designed-in features. These contain oversized bearings with the dynamic load rating increased by 40 % as well as a special radial shaft sealing ring with an additional protective lip. To guarantee the best signal quality the bearings are not primarily designed for high speeds, but rather for high shock loads up to 450 g. The min. degree of protection is IP66 / IP67 with an operating temperature up to 100 °C. Products and Accessories Looper Encoder Coupling Connector Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other applications in Steel Making Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Glass Panel Position Measurement using Laser Distance Sensors

Glass

Glass Panel Position Measurement using Laser Distance Sensors

Glass

In the area of the facility where glass panels are staged, a servodriven actuator system identifies and tracks the leading edge of the glass as it moves along the facility’s conveyor line. After the conveyor apparatus picks up the glass, it is unable to compensate for the non-standard height of the pallets used to transport andstore the glass panels in a horizontal position. Home Case Studies Glass Panel Position Measurement using Laser Distance Sensors Glass Panel Position Measurement using Laser Distance Sensors Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Easy installation thanks to visible laser beam Easy configuration thanks to the free software Operation in the largest temperature range (-40°C to +60°C) possible Measuring ranges up to 100 m on natural surfaces | Measuring ranges up to 500 m on reflective foil Accuracy ± 1mm | Measurements can be acquired by a PLC or PC | Maintenance-free operation Task Leading manufacturers of insulating glass units require a sensor solution that monitors and precisely adjusts glass panel positioning on a production conveyor belt, based on the exact height of non-standard pallets. These pallets are used to transport and store glass panels horizontally. Solution Dimetix Laser Distance Sensors offer several methods of communicating tocontrol systems commonly used in manufacturing and productionapplications. In the area of the facility where glass panels are staged, a servodriven actuator system identifies and tracks the leading edge of the glass as it moves along the facility’s conveyor line. After the conveyor apparatus picks up the glass, it is unable to compensate for the non-standard height of the pallets used to transport andstore the glass panels in a horizontal position. Dimetix Laser Distance Sensor measure the height of the pallet and adjust a position to stop the glass panel. After the panel is halted, the machine begins tilting it onto the pallet precisely at the point where there is no chance the glass can slide or be misplaced. It is then gently placed on the pallets next to other glass panels. Products and Accessories Laser Distance Meter Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Explore our solutions

Foundry,Ladle,With,Liquid,Steel.,Liftable,Ladle,Turret,Of,Continuous

Online condition-based Monitoring / Predictive Maintenance of LHF

Steel & Rolling Mills, Steel Making

Online condition-based Monitoring / Predictive Maintenance of LHF

Steel & Rolling Mills, Steel Making

Compact infrared thermal imaging camera was used for the continuous temperature monitoring of each zone. Alarm generated if zone temperature exceeds set points. Hot spot detector scans the entire critical asset and easily identifies the spot with maximum refractory erosion. Home Case Studies Online condition-based Monitoring / Predictive Maintenance of LHF Online condition-based Monitoring / Predictive Maintenance of LHF Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Increased efficiency: Ladle lifetime improvement with early detection allowing for selective repairs as opposed to full lining Improve safety level: Prevent breakouts and reduce risk of damage to personnel & plant equipment Avoid unscheduled downtime: Avoids costly machinery damage and days to clean-up Challenges The customer faced the challenge of measuring the temperature of ladle shell when the hot metal is inside so that any punctures can be identified in time Solution Compact infrared thermal imaging camera provided the ideal solution Zones Monitoring: Each zone temperature was continuously monitored.If zone temperature exceeded above 300⁰C, an alarm was generated. Hot Spot Detection: Hot spot detector scanned the entire critical asset and easily identified the spot with maximum refractory erosion. Predictive Maintenance: Real time system running 365 / 24/ 7 days, warning of excessive shell temperature from refractory degradation. Products and Accessories Thermal Imaging Camera Water Cooling Jacket Air Purge Unit Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Applications in Steel Making View All Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE

Width Measurement for Camber detection

CRM, Hot Rolling Mill, Steel & Rolling Mills

Width Measurement for Camber detection

CRM, Hot Rolling Mill, Steel & Rolling Mills

Home Case Studies Width Measurement for Camber detection Width Measurement for Camber detection Contact based length measurement. Inaccurate and manual process was not practical for continuous casting mill. Non-contact laser distance meter to work on hot surface upto 1300°C. 200°C ambient temperature with water cooling. 3nos of digital output and 1nos of Analog (4-20mA). Works on even dark surface (gray slabs). Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Accurate width measurement for camber detection. Precise measurement : +/-1mm accuracy with 2σ Stainless housing with double walled cooling for ambient temperature upto 200 °C Works on product surface upto 1300 °C Analog and digital outputs Challenges Contact based length measurement Inaccurate and manual process was not practical for continuous casting mill Slab hitting the tunnel furnace refractory causing unplanned breakdown Solution Non-contact laser distance meter to work on hot surface upto 13000C. 200C ambient temperature with water cooling 3nos of digital output and 1nos of Analog (4-20mA) Works on even dark surface (gray slabs) Products and Accessories Light Barriers Technical Specifications Accuracy ± 1mm Repeatability ± 0.3 mm Measuring ranges up to 100 m on natural surfaces Measuring ranges up to 500 m on reflective foil Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Manual rod to check the camber measurement Case Studies Other Solutions – Hot Rolling Mill Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Detection of large hollow pipe using proximity sensors

Tubes and Pipes

Detection of large hollow pipe using proximity sensors

Tubes and Pipes

Bouncing effect in the pipe mill mechanically damages the proximity. Circulating trolley systems, cold strip lines, lifting bar conveyors, and other equipment are also used, in addition to roller conveyor systems. Inductive proximity switches were used, which provided safe operation for large sensing distance, and even in the presence of water, dust, emulsions and oils. Home Case Studies Detection of large hollow pipe using proximity sensors Detection of large hollow pipe using proximity sensors Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Reliable detection of hot objects up to up to +230 °C High operating distance to preserve sensors from mechanical shocks Safe operation also with water, fog, snow, vapor or dust Adjustable response temperature Extremely high resistance to pollution Challenges Bouncing effect in the pipe mill mechanically damages the proximity Circulating trolley systems, cold strip lines, lifting bar conveyors, and other equipment are also used, in addition to roller conveyor systems Solution Inductive proximity switches were used, which provided safe operation for large sensing distance, and even in the presence of water, dust, emulsions and oils. Sn: 140 mm IP 67 Temp: -25 to +70 °C Supply voltage: 20-260 V AC/DC Cable length: 2,5,10,15,20 m Cable MOC: Silicone cable No. of wires: 3-wire Housing (Ǿ): 110x110x43 Cable conduit protection available Products and Accessories Inductive Proximity Sensors Cable Protection Conduits Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

We are a trusted automation solution partner for Integrated Steel Plants.

How do we help you to find the right solution?

We work with you to create a customised solution which meets your requirements and solves your problem in the most cost-effective way. Get in touch to get started.

Know which product you need?

Browse products