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Hoist / Drum: Improved operating reliability and positioning accuracy at the ladle crane
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 Hoist /Drum: Improved operating reliability and positioning accuracy at the ladle crane Hoist / Drum: Improved operating reliability and positioning accuracy at the ladle crane 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 braking when overspeed is detected Precise switching of hoist positions Configure parameters quickly and easily Preset shortens downtimes after rope change Before: Hoist drum with mechanical rotary cam limit switch, but without overspeed detection. Bottom right, the new holding brake. Task Fundamentally improve the operating reliability and positioningaccuracy of the ladle crane hoist used in steel production byimplementing the following measures: • Replacement of the existing mechanical cam limitswitch with an electronic position switch that ensures significantly higher accuracy • Additional implementation of an electronic overspeed switch to realize overspeed detection as well as an emergency break After: Hoist drum with U-ONE basic unit and holding brake. The photo right shows the U-ONE electronic modules in the switchboard Solution 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• The following electronic modules were installed, well-protected in the switchboard: • FOC decoder • Electronic position switch (ERC) with 6 relay outputs and preset input to facilitate plant adjustments • Electronic overspeed switch (EGS) with 2 relay outputs and integrated system check function Products and Accessories Universal 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 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, material handling
November 16, 2022
Hoist / Drum: U-ONE ensures higher positioning accuracy and less maintenance time and costs for the RTG
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 Hoist /Drum: Improved operating reliability and positioning accuracy at the ladle crane Hoist / Drum: U-ONE ensures higher positioning accuracy and less maintenance time and costs for the RTG 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 Universal encoder system U-ONE replaces inaccurate mechanical cam limit switches EMC safe signal transmission via fiber optic cable Time-saving preset function to make adjustments after replacing the wire rope Easy to extend with additional speed measurement and monitoring functionality Mechanical cam limit switch for position monitoring at the hoist of a RTG crane. Task PSA EXOLGAN TERMINAL BUENOS AIRESMechanical cam limit switches were installed on the drum sideof the SISU RTG. Resetting these mechanical cam limit switches,for example after replacing the rope, was extremely time-consuming.Moreover, the switching points no longer fulfilled theaccuracy requirements demanded in today’s world. Then therewas the customer’s wish to install overspeed protection on thedrum side as well as the option to acquire speed data. The universal encoder system U-ONE reduces maintenance timestogether with an increase of position accuracy. Solution The U-ONE® universal encoder system fulfils all of the customer’srequirements. It is possible to carry out minor mechanical modificationson-site to ensure installing the basic unit presents nodifficulty. Evaluation electronics in the switchboard provide thedesired switching points, overspeed protection as well as speeddata. And, thanks to the software included in the scope of supply,switching points and operating ranges are user programmable.Signals between the basic unit and the electronics are transmittedEMC safe via fiber optic cable. Products and Accessories Universal 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 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, material handling
October 29, 2022
Switching accuracy at the crane hoist by compact incremental encoder with electronic over speed switch
The EGS series of electronic overspeed switches from Johannes Huber Giessen are the ideal solution for heavy -duty applications that demand the highest levels of precision and reliability. These devices make it possible to monitor both overspeeds and underspeeds across the complete speed range with utmost precision. Home Case Studies Significantly higher switching accuracy at the crane hoist thanks to compact incremental encoder with additional electronic overspeed switch Higher switching accuracy at the crane hoist by compact incremental encoder with additional electronic overspeed switch 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 Modern replacement solution for mechanical overspeed switches Compact design with an incremental output and electronic overspeed switch Pre-programmed switching speed Easy mechanical and electrical exchangeability Before: Tacho generator with attached mechanical overspeed switch for speed measurement and monitoring at the hoist of a RMG crane. Challenges A tacho generator and an additionally attached mechanical overspeed switch are responsible for speed measurements and overspeed monitoring at the hoist. Due to its design the mechanical overspeed switch has a switching tolerance of ± 75 rpm, which leads to inaccuracy at the desired switching point. Moreover, the mechanical overspeed switch only reacts to speeds of 700 rpm and above. The signal quality of the tacho generator does not o er the precision required in today’s world. The customer wished for a replacement solution that corresponds to current state of the art technology. Products and Accessories Speed feedback for auxiliary drives Couplings Adapter Shaft After: Significant more precise speed monitoring by the incremental encoder FG 2 with integrated electronic overspeed switch. Solution Based on the experience gained from previous modernization projects the implemented solution saw the installation of an incremental encoder FG 2 with an integrated electronic overspeed switch (option S). In addition to the incremental position value this compact encoder solution o ers a switching speed set ex works. The electronic overspeed switch provides signifi cantly more accurate overspeed monitoring. The switching speed of 2550 rpm was adopted from the previous solution 1:1. Not only is the overall length now distinctly shorter, this solution requires no changes to the existing mechanical interface. The entire conversion was implemented quickly and easily. 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
Tags: Crane
January 5, 2022
Replacing mechanical cam limit switches on cranes without PLC
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
Tags: Crane
January 4, 2022
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
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