Area: Converter
Converter /Tilting angle: Exchange solution for tilting angle monitoring
Home Case Studies Converter /Tilting angle: Exchange solution for tilting angle monitoring 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. Converter /Tilting angle: Exchange solution for tilting angle monitoring 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 Direct mounting / elimination distribution gear Higher accuracy Easy configuration of switching points Fast commissioning and restart after preset Before: Mechanical cam limit switch and absolute encoder mounted by using an additional distribution gear Challenges In steel making plants tilting angles of converters are measured by absolute encoders and monitored by mechanical cam limit switches. The sensors are normally mounted by using an additional distribution gear, which causes mechanical play and inaccuracy. Furthermore, the mechanical cam limit switches are difficult to preset and not precise enough. After: Electronic position switches and absolute encoder in one unit directly mounted without distribution gear Solution The universal encoder system U-ONE-(SAFETY-)Compact provides the same outputs as the old solution, but in just one compact and robust unit:• Absolute encoder• Electronic position switches The unit can be mounted directly to the application shaft without using any distribution gear. For this Hübner Giessen provides special torsion resistant double-joint couplings. The switching points are easy to configure and the system can be restarted fastly after preset. Optionally available with safety certification SIL 2/PL d. Products and Accessories Universal Encoder 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
Converter / Lance position: New solution for positioning of the oxygen lance
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 Converter / Lance position: New solution for positioning of the oxygen lance Converter / Lance position: New solution for positioning of the oxygen lance 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 No need of complex encoder constructions Higher accuracy Easy configuration of switching points Precise and reliable positioning Before: Mechanical cam limit switch and absolute encoder mounted by using an additional distribution gear. Challenges The customer needed a solution to detect the lance position for precise and reliable positioning. The old solution included an absolute encoder for current position values and a mechanical cam limit switch for position range monitoring. The limited positioning accuracy due to mechanical play was caused by the necessary installation of an additional distribution gear. The task was to find a new solution instead of the old one with mechanical cam limit switch and absolute encoder. After: Electronic position switches and absolute encoder in one unit directly mounted without distribution gear. Solution To get the same outputs as before Hübner Giessen provides the universal encoder system U-ONE(-SAFETY)-Compact with both outputs in one unit: • Absolute encoder • Electronic position switches The unit can be mounted directly to the application shaft without using any distribution gear. For this Hübner Giessen provides special double-joint couplings. The switching points are easy to configure and the system can be restarted fastly after preset. Optionally available with safety certification SIL 2 / PL d. Products and Accessories Universal Encoder 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
Online Condition Based Monitoring of EAF / Converter for Preventative Maintenance
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 Online Condition based Monitoring of EAF for Preventative Maintenance Online Condition based Monitoring of EAF for Preventative Maintenance 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 No wiring: Non-contact temperature measurement. Scans full bottom shell. Multiple area /ROI possible to define to get 4-20mA output Intuitive identification of hot spot. Software automatically finds hot spots Challenges High temperatures cause wires to melt leading to loss of thermocouple readings. Plant operators need to wait until the next planned shutdown to carry out change in wires and undertake repairs. Furthermore, thermocouples only provide point temperature readings and therefore it becomes difficult to identify where the hot spots are being developed. Point measurement thermocouples: Average only 9 point measurements possible with thermocouples. High maintenance cost: Not possible to change wiring while furnace in operations Solution Compact IR thermal imaging camera was installed to provide a temperature map of the complete bottom shell 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 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