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Incremental heavy-duty encoders defy the most adverse conditions in mining operations to ensure reliable speed control
Home Case Studies Incremental heavy-duty encoders defy the most adverse conditions in mining operations to ensure reliable speed control The skip-car control mechanism utilised to date included two mechanical, geared cam limit switches that are time consuming to program. Upgrading to meet modern demands required suitable components for measuring actual values that are not only characterized by their high accuracy and functional reliability, but are also easy to program. Hübner Giessen replaced one of the geared cam limit switches with a series FG 4 K incremental encoder and an AMS 4 K type absolute encoder with integrated SSI interface. Incremental heavy-duty encoders defy the most adverse conditions in mining operations to ensure reliable speed control 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 hollow shaft attachment to the motor shaft Optimum compensation for oscillation and shock loads Insulated attachment with hybrid bearings and customized torque bracket Effectively avoid destructive shaft currents Conveyor drive station in open cast mining. Challenges Conveyor belt components in particular must be able to permanently withstand the powerful effects of oscillation and vibration. These not only result from the length of the conveyor system or the material being transported. Other causes can be traced back to the design of the drive station, the drive solutions, transfer points, the condition of the belts and similar reasons. The inverter-controlled drives can cause shaft currents that place a heavy strain on the bearings of the encoder system and even destroy them over time. Then there are external factors such as dust, dirt and moisture as well as extreme temperature fluctuations depending on the time of day, and extreme cold or heat depending on the region where the conveyor system is installed. Incremental encoder FGHJ 5 with special hybrid bearings in a heavy duty housing. Solution To ensure optimum compensation for the extreme oscillation and vibration loads we recommended fitting hollow-shaft encoders in conjunction with torque brackets. The heavy duty encoder FGHJ 5 has hybrid bearings; when fitted in combination with the insulated torque bracket and, if required, an insulated adapter shaft they can effectively prevent the negative influence of shaft currents on the service life of the encoders. In line with requirements it is possible to augment the incremental encoders with an overspeed switch integrated in the second terminal box to guarantee additional protection against overspeeds and underspeeds and safeguard special safety-related functions. Products and Accessories Speed feedback for main drives Tether Heavy duty programmable overspeed switch 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 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
Tags: Crane, material handling
December 30, 2021
MAG with large split pulse wheel for improved control accuracy
The skip-car control mechanism utilised to date included two mechanical, geared cam limit switches that are time consuming to program. Upgrading to meet modern demands required suitable components for measuring actual values that are not only characterized by their high accuracy and functional reliability, but are also easy to program. Hübner Giessen replaced one of the geared cam limit switches with a series FG 4 K incremental encoder and an AMS 4 K type absolute encoder with integrated SSI interface. Home Case Studies MAG with large split pulse wheel for improved control accuracy MAG with large split pulse wheel for improved control accuracy 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 Custom-made attachment solution with pulse wheel diameter of 1300 mm Easy retrofit solution thanks to split pulse wheel and adapter ring Significantly higher resolution in comparison with original tooth wheel scanning solution Optimized sensor systems compensate eccentricity to ensure the drive pulley runs true Before: The resolution of the existing inductive tooth wheel scanning solution is no longer sufficient for high-precision speed control. Challenges The objective is to improve the accuracy of the closed-loop speed control system on a Koepe winder with an integrated motor. The resolution of the existing inductive tooth wheel scanning solution no longer meets customer requirements, so that a new sensor system is needed. The Koepe principle utilizing an integrated motor sees a drive pulley rotate around a fixed axle. Consequently, the magnetic scale of the speed measuring sensor cannot be attached to a rotating shaft. The task was made even more difficult by the fact that the drive pulley runs out of true (eccentricity) by several millimetres, which is something the measuring system must compensate. After: The tailor-made magnetic encoder system MAG 1300 provides 2460 square pulses per revolution. Solution An encoder system was developed to meet the exact requirements of the application. This consists of a pulse wheel with a diameter of 1300 mm and a magnetic scale. The pulse wheel has a split design consisting of two halves to considerably simplify installation. Both pulse wheel halves are precisely bolted to an equally split adapter ring fastened to the drive pulley. The sensor system is well-protected in a scanning head, which is fastened to a fixed part of the Koepe winder with a special bracket. Optimized at the maximum gap between the pulse wheel and scanning head the measuring system supplies 2460 square wave pulses per revolution. Products and Accessories Magnetic Encoder Heavy duty absolute encoder Heavy duty programmable overspeed switch 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 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. 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Tags: Crane, material handling
December 23, 2021
AMPN 41 provides safe position monitoring at slewing gear of a bucket wheel excavator
Electronic position switch ERC 40 enclosed in robust housing for use in extreme ambient conditions. The new solution offers customers the following benefits: Higher switching accuracy when approaching end position limits, Less downtimes, User-friendly calibration via preset input, Save and import parameter data sets, Time-saving safety check (switch test function), Additional real-time position data (4 – 20 mA output), Reduced type variety and costs for backup devices, Integrated status monitoring (temperature, speed, voltage, system limits and so on) with active signal output for time-saving identification in the event of a fault condition Home Case Studies AMPN 41 provides safe position monitoring at slewing gear of a bucket wheel excavator AMPN 41 provides safe position monitoring at slewing gear of a bucket wheel excavator 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 Highly precise replacement solution for inaccurate mechanical cam limit switches PROFIsafe via PROFINET for direct connection to the safety PLC Certified safety ensures uncomplicated acceptance test High levels of availability even in mining operations subject to extreme environmental conditions Before: Frame construction for the slewing gear between the superstructure and substructure of the excavator with several mechanical cam limit switches for position monitoring. Challenges It is planned to equip a bucket wheel excavator with the latest automation and safety technologies as part of a complete modernisation project. To achieve the required safety categories identified by a risk assessment, safe position values are required for both slewing gear mechanisms between the superstructure and substructure of the excavator as well as between the discharging boom and the substructure of the excavator. By contrast standard position values are sufficient to determine the position of the crawler tracks. After: The safety certified absolute encoder AMPN 41 provides safe position actual values to the safety plc. The Hübner Giessen solution Equipped with a safe PROFINET interface that uses the PROFIsafe protocol the AMPN 41 multiturn absolute encoders to be installed at the slewing gear mechanisms are certified for applications up to Safety Integrity Level (SIL) CL3 to EN 61508 and PL e to EN ISO13849. That saves the user having to provide separate verification of the functional safety of the position sensors. Absolute encoders AMP 40 equipped with a standard PROFIBUS interface will be installed at the crawler tracks. Robust, form-locked process coupling and the dedicated constructional design of the encoders for use in mining operations subject to extreme environmental conditions ensure position data is reliably made available at the safety level required for the respective application. Products and Accessories Electronic position switch Coupling Heavy duty programmable overspeed switch 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 Mining & Material Handling 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
Tags: Crane, Large Machinery, material handling
December 22, 2021
Robust encoders ensure more precision and less downtimes
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 Robust encoders ensure more precision and less downtimes Robust encoders ensure more precision and less downtimes 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 Greater functional component reliability Higher converter plant availability More precise measurement signals despite shock and vibration loads Easy and time-saving programming Before: Old skip-car control mechanism with two mechanical geared cam limit switches. Challenges The skip-car control mechanism utilised to date included two mechanical, geared cam limit switches that are time consuming to program. The mechanical overspeed switch utilized can prove problematical when subjected to shock and vibration loads. Neither of these components exhibits the required precision and as such are not suitable to meet the modern-day requirements of steel mill operations. After: More precise signals because of robust combination of bearing block and heavy duty encoders. Solution Upgrading to meet modern demands required suitable components for measuring actual values that are not only characterized by their high accuracy and functional reliability, but are also easy to program. Hübner Giessen replaced one of the geared cam limit switches with a series FG 4 K incremental encoder and an AMS 4 K type absolute encoder with integrated SSI interface. Fitting the devices to a bearing block increases their resistance to shock and vibration loads and compensates the mechanical tolerances of the installed, previous transfer gearbox. The other cam limit switch will also be replaced in a second modernizing step as will the mechanical overspeed switch be replaced by a programmable electronic overspeed switch. Products and Accessories Heavy duty programmable overspeed switch 1:1 Replacement for Mechanical Cam Limit Switch Speed feedback for main drives Couplings Magnetic Bearingless Tether Adapter Shaft 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
December 14, 2021
Bearingless encoder system MAG withstands permanently extreme environmental conditions in the roll stand
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 Bearingless encoder system MAG withstands permanently extreme environmental conditions in the roll stand Bearingless encoder system MAG withstands permanently extreme environmental conditions in the roll 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 Designed for high shock and vibration loads, aggressive cooling emulsions Tailor-made solution features an installation width of just 10 mm Special stainless-steel ring ensure a long service life Interference-free speed measurements of the metal strip for optimum drive control Sensors for strip speed measurement are exposed to extreme ambient conditions in the area of the measuring roll. Challenges The actual feedback value of the effective speed of the metal strip is required to effectively regulate the roll stand drives. It is possible to measure this value using suitable sensors located at the drive measuring roller between the stands. Shock and vibration loads as well as aggressive cooling emulsions mean the devices need to withstand extreme environmental conditions. In addition, limited installation space made it necessary to adapt the sensor system. Due to the loads mentioned above a measuring system installed to date was unable to supply interference-free speed signals. Tailor-made MAG system solution with extremely slim design and special Stainless steel bandage to protect the MAG pulse wheel. Solution Following discussions with the end customer Johannes Hübner Giessen installed a suitable measuring system with magnetic sensor technology that could be adapted to suit the conditions. The selected MAG 260 consists of a pulse wheel with an outside diameter of 260 mm as well as a scanning head with completely encapsulated electronics sealed to IP67. The bearingless system is unaffected by shock and vibration; it supplies interference-free signals even when exposed to extreme high quantities of aggressive liquids and vapours. Without using the reference pulse it was possible to implement the extremely slim 10 mm design width as needed. Products and Accessories Magnetic Bearingless 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
December 13, 2021
Encoder retrofitted directly to the tandem drive ensures trouble-free rolling mill operations
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 Encoder retrofitted directly to the tandem drive ensures trouble-free rolling mill operations Encoder retrofitted directly to the tandem drive ensures trouble-free rolling mill operations 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 Straightforward retrofit without free shaft end Bearingless magnetic encoder with split pulse wheel and narrow construction Replacement for belt drive that required intensive maintenance Also suitable for high speed and rapid reversing movements Motor shaft of a rolling mill tandem motor with mounted MAG-G system. Challenges Only the rear motor of tandem drives has a shaft end available to which an encoder can be attached. However, a speed signal is also required from the front motor for synchronizing purposes in tandem operations or as motor feedback in single-motor operations (decoupled mode of operation). This is often generated by an encoder driven by a toothed belt, but typical disadvantages of this solution (tension, alignment, wear etc.) have a negative impact on the quality of the signal and lead to increased servicing costs. The better solution is a special encoder that can be attached directly to the shaft of the front motor without having to separate the tandem motors. Bearingless magnetic encoder system MAG-G with split pulse wheel and scanning head. Solution To be able to mount an encoder where there is no shaft end available Johannes Hübner Giessen installed its bearingless, magnetic type encoders MAG-G. Consisting of two half shells they can be retrofi tted at any point of a rotating shaft. The staggered design of the two half shells ensures the construction is suitable for applications with high speed and rapid reversing movements. The bearingless version o ers protection against shaft currents, it is wear free and also suitable for large shaft diameters. Thanks to its slim design width of just 30 mm the MAG-G system is easy to integrate in existing solutions. Products and Accessories Magnetic Bearingless 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
December 2, 2021
Electronic overspeed switch EGS 41 ensures safe rolling mill operations
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 Electronic overspeed switch EGS 41 ensures safe rolling mill operations Electronic overspeed switch EGS 41 ensures safe rolling mill operations 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 Safely-Limited Speed (SLS) during maintenance and setup procedures Adhering to provisions in the Machinery Directive relating to the protection of persons Straightforward implementation with certified EGS 41 (SIL 2 / PL d) User-friendly configuration, storage and switch tests Rolling mill in a hot rolling mill. Challenges 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: Setup procedures with rotating rollers Maintenance work under electrical voltage The risks of such situations can be significantly reduced by implementing the safety function “Safely-Limited Speed” (SLS). SLS can be realized by using an overspeed switch that operates independent of the encoder and fulfils the special safety requirements (Safety Integrity Level SIL / Performance Level PL). Electronic overspeed switch EGS 41 mounted on an incremental encoder FGH 6. Solution To meet these requirements Johannes Hübner Giessen supplies the overspeed switch EGS 41, which is certified up to SIL 2 to IEC 61508 and PL d to DIN EN ISO 13849. In addition to two safe switching outputs for speed monitoring of overspeeds and underspeeds it offers integrated standstill functionality as well as an integrated diagnostics switch to monitor safety functions integrated in the device. The programming software included in the scope of supply supports user-friendly parameterization via a USB interface. Products and Accessories Heavy duty programmable overspeed switch Adapter Shaft Tether 1:1 Replacement for Mechanical Cam Limit Switch Speed feedback for main drives 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
Tags: Hot Rolling Mills
November 29, 2021
Special looper encoders withstand the most extreme operating conditions in hot roll stands
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
Tags: Steel Making
November 25, 2021
Higher control accuracy in hot rolling mill due to direct encoder attachment
Home Case Studies Higher control accuracy in hot rolling mill due to direct encoder attachment The blast furnace skip hoist is protected against overspeed on the motor side by a mechanical overspeed switch with integrated speed increasing gear. The universal encoder system U-ONE® is to replace the outdated sensor systems on both the motor and drum sides. Thanks to its modular design it is possible to adapt the system to meet all of the customer requirements. Direct attachment of the basic unit eliminates mechanical inaccuracies resulting from gearbox backlash and supports improved control response. Higher control accuracy in hot rolling mill due to direct encoder attachment 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 mechanical play because solution requires no transfer gearbox or additional couplings Directly attachable compact U-ONE basic unit EMI safe signal transmission via fiber optic cable Improved material quality due to higher control accuracy Before: The assembly of encoder and mechanical cam limit switches with transfer gearbox and additional couplings produces control inaccuracies cause of mechanical play. Challenges Side guides are used to centre the metal strips upstream of the roll stands. In some cases, mechanical cam limit switches and / or absolute encoders are still used for position detection and control. Attachment to the available shaft end of the drive is a widespread solution. To improve control accuracy and, as a consequence, the quality of the material the customer desires a directly mounted, compact solution without a downstream transfer gearbox (gear backlash). The same demands apply to adjusting the screw downs for thickness control. Modular U-ONE-System with directly attachable basic unit creates greater control accuracy. Solution The advantage of the modular U-ONE® system from Johannes Hübner Giessen is that just the universal basic device is mounted to the side-guide, while the functional modules are housed externally in the switchboard. A fiber optic cable is used to achieve the EMI safe connection, a solution that offers considerable savings with regard to cabling time and costs. The system is programmed via a central USB interface. The system is easily extended with the series (side-by-side) plug-in function modules in conjunction with the low-cost of spare parts. 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 Solutions in Hot Rolling Mills 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
Tags: Hot Rolling Mills
November 24, 2021
Overspeed switch EGSH 41 ensures safely limited speed in the mill stand
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
November 22, 2021
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