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Page 6 of 13
Page 6 of 13
Converter /Tilting angle: Exchange solution for tilting angle monitoring
Home Case Studies Converter /Tilting angle: Exchange solution for tilting angle monitoring Compact IR thermal imaging camera was installed to provide a temperature map of the bottom shell. The cameral scans the full bottom of the shell giving options to define multiple areas /ROI to get 4-20mA output. Software automatically finds hot spots enable timely preventative maintenance. Converter /Tilting angle: Exchange solution for tilting angle monitoring Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Direct mounting / elimination distribution gear Higher accuracy Easy configuration of switching points Fast commissioning and restart after preset Before: Mechanical cam limit switch and absolute encoder mounted by using an additional distribution gear Challenges In steel making plants tilting angles of converters are measured by absolute encoders and monitored by mechanical cam limit switches. The sensors are normally mounted by using an additional distribution gear, which causes mechanical play and inaccuracy. Furthermore, the mechanical cam limit switches are difficult to preset and not precise enough. After: Electronic position switches and absolute encoder in one unit directly mounted without distribution gear Solution The universal encoder system U-ONE-(SAFETY-)Compact provides the same outputs as the old solution, but in just one compact and robust unit:• Absolute encoder• Electronic position switches The unit can be mounted directly to the application shaft without using any distribution gear. For this Hübner Giessen provides special torsion resistant double-joint couplings. The switching points are easy to configure and the system can be restarted fastly after preset. Optionally available with safety certification SIL 2/PL d. Products and Accessories Universal Encoder Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other applications in Steel Making Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All
Tags: converter, Steel Making
October 26, 2021
Converter / Lance position: New solution for positioning of the oxygen lance
Compact IR thermal imaging camera was installed to provide a temperature map of the bottom shell. The cameral scans the full bottom of the shell giving options to define multiple areas /ROI to get 4-20mA output. Software automatically finds hot spots enable timely preventative maintenance. Home Case Studies Converter / Lance position: New solution for positioning of the oxygen lance Converter / Lance position: New solution for positioning of the oxygen lance Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection No need of complex encoder constructions Higher accuracy Easy configuration of switching points Precise and reliable positioning Before: Mechanical cam limit switch and absolute encoder mounted by using an additional distribution gear. Challenges The customer needed a solution to detect the lance position for precise and reliable positioning. The old solution included an absolute encoder for current position values and a mechanical cam limit switch for position range monitoring. The limited positioning accuracy due to mechanical play was caused by the necessary installation of an additional distribution gear. The task was to find a new solution instead of the old one with mechanical cam limit switch and absolute encoder. After: Electronic position switches and absolute encoder in one unit directly mounted without distribution gear. Solution To get the same outputs as before Hübner Giessen provides the universal encoder system U-ONE(-SAFETY)-Compact with both outputs in one unit: • Absolute encoder • Electronic position switches The unit can be mounted directly to the application shaft without using any distribution gear. For this Hübner Giessen provides special double-joint couplings. The switching points are easy to configure and the system can be restarted fastly after preset. Optionally available with safety certification SIL 2 / PL d. Products and Accessories Universal Encoder Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other applications in Steel Making Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All
Tags: Steel Making
October 11, 2021
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 limit switchwith an electronic position switch that ensures significantlyhigher accuracy Additional implementation of an electronic overspeed switchto realize overspeed detection as well as an emergency break(not included in scope of supply of Hübner Giessen) 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 adouble joint coupling on a tailor-made base plate construction Signal transmission via fiber optic cable preventsEMC problems The following electronic modules were installed,well-protected in the switchboard: FOC decoder Electronic position switch (ERC) with 6 relay outputs andpreset input to facilitate plant adjustments Electronic overspeed switch (EGS) with 2 relay outputs andintegrated 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
October 8, 2021
Slab Detection in Excessive Steam (HMD)
On the roughing mill exit, there is a lot of steam due to the spray header. The steam obstructs field of view of the traditional scanning type HMDs as result, occasionally the signal flickers for a millisecond. The next generation HMD 4.0 from Proxitron have intelligent software features which allows to set dual thresholds (hysteresis). Home Products Sensor Technology Slab Detection in Excessive Steam (HMD) Slab Detection in Excessive Steam (HMD) 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 HMD under most aggressive environment Flicker free operation due to dual threshold (hysteresis) setting option Adjustable response temperature Withstand ambient 2000C (water-cooling) and 2900C (w/o water cooling) Diagnostic alarm feature Challenges On the roughing mill exit, there is a lot of steam due to the spray header. The steam obstructs field of view of the traditional scanning type HMDs as result, occasionally the signal flickers for a millisecond. Solution The next generation HMD 4.0 from Proxitron have intelligent software features which allows to set dual thresholds (hysteresis). The upper threshold setting say at 6000C and lower threshold setting at 2000C. So when slab at 10000C cross the field of view of the HMD 4.0 detects the slab but due to momentarily presence of steam, slab temperature may appear to be lower than 600C will not cause the signal to flicker. Only if the temperature goes below the lower threshold setting i.e. 200C will HMD shows slab is not present. Products and Accessories Hot Metal Detectors Accessories 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 View All
Tags: Slab detection
Precise Looper Position Feedback
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. For this application Johannes Hübner Giessen developed a special looper encoder, which boasts a considerably longer lifetime thanks to especially designed-in features. Home Case Studies Precise looper position feedback Rolling mills /Looper: 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 Special looper encoders withstand the most extreme operating conditions in hot roll stands 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. The Hübner Giessen 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 Heavy duty stainless steel 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 Solutions in Hot Rolling Mills – Finishing Mills View All
Tags: Hot Rolling Mills
Strip detection after laminar cooling
Due to low temperature of the strip at the laminar table, the response from a standard scanning type HMD was unstable. Proxitron light barrier was installed at the down coiler. It provided higher functional reserve up to 750 m Home Case Studies Strip detection after laminar cooling Strip detection after laminar cooling 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 Task Stable performance was required while strip detection after laminar cooling, in harsh environment conditions Challenges Due to low temperature of the strip at the laminar table, the response from a standard scanning type HMD was unstable. Moreover the environment conditions were challenging:- High ambient temperature and fumes under the strip. Presence of scales and dust generating from them, led to degraded performance of light barrier. Continuous water falling on the conveyor table Solution Proxitron light barrier was installed at the down coiler. It provided higher functional reserve up to 750 m. Higher the functional reserve, better is the stability of performance against pollutions such as water, steam, fumes. Customer Benefit Resistant to contamination due to steam, dust, fumes. Stable and uninterrupted performance Accurate and reliable Products and Accessories Light barriers 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: Down Coiler
Converter/ Inclined hoist: Robust encoders ensure more precision and less downtimes
Home Case Studies Robust encoders ensure more precision and less downtimes 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. Converter/ Inclined hoist: 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. Task 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. The Hübner Giessen 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 Speed feedback for main drives 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. 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 7, 2021
Tilt Angle Sensor For Radial Gate Positioning
To calculate the flow of water via measuring the tilt angle of radial gate. Safety limit detection i.e. Indication if the radial gate is fully open or fully closed. Environment conditions included high humidity and huge vibrations. Home Case Studies Tilt Angle Sensor For Radial Gate Positioning Tilt Angle Sensor For Radial Gate Positioning 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 Tilt angle sensor with high price to performance ratio Cost effective and reliable IP68 Inductive technology Oil filled to dampen oscillations Challenges To calculate the flow of water via measuring the tilt angle of radial gate. Safety limit detection i.e. Indication if the radial gate is fully open or fully closed Environment conditions included High humidity Huge vibrations Solution Tilt angle sensor with high price to performance ratio Cost effective and reliable IP68 Inductive technology Oil filled to dampen oscillations 4nos Control Output: 4 fast PNP outputs ; 5-30V/200mA 2nos Relay Output: End point detection ; Potential free Site supervision to assist in installation Matching the 0o position of gate with 4mA Correct mounting position i.e. anticlockwise Field experience to troubleshoot: Continuity check, carbon on terminals, shielding check Training of site engineers Products and Accessories Tilt Angle Sensor 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 Power 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: hydropwer, radial gate, Tilt angle sensor
Blast furnace/Skip hoists: Retrofitting a U-ONE provides higher accuracy and improves availability
Home Case Studies Retrofitting Availability 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. Blast furnace/Skip hoists : Retrofitting a U-ONE provides higher accuracy and improves availability 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 Higher production quality and throughput Universal encoder system U-ONE replaces inaccurate mechanical components Directly attachable compact basic U-ONE unit EMC safe signal transmission via fiber optic cable Electronic function modules protected in switchboard Before: The sensors mounted at an intermediate gear can‘t reach thenecessary accuracy for precise positioning. Task The blast furnace skip hoist is protected against overspeed on the motor side by a mechanical overspeed switch with integrated speed increasing gear. On the drum side two absolute encoders mounted on a distribution gearbox supply position signals. As part of a modernization project outdated sensors need to be replaced with up-to-date systems. Objectives include simplification of mechanical attachments, elimination of inaccuracies as well as all-round better control response. In addition, susceptibility to EM disturbances is to be reduced and, as a consequence, increase the robustness and availability of the installation. After: The direct mounted basic unit of the universal encoder system U-ONE® provides precise signals to the electronic modules in the control cabinet. The Hübner Giessen solution 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. Signal transmission via fiber optic cable eliminates the effects of EMC issues. The EGS module facilitates easy programming of the switching points for overspeed monitoring purposes. The AMS module with SSI interface provides values for position sensing. In addition, the ERC module allows users to conveniently program position switching points without modifying the programming of the PLC. 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: Crane, material handling
Coil detection
On high grade rolling, the exit coil temperature radiated heat leading malfunctioning of signal of existing light barrier. Water cooling line provision was not available. Reliable coils detection regardless of their temperature, cold or warm, up to 600°C. Home Case Studies Coil detection Coil detection 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 Uninterrupted coil detection for maximum machine availability and uptime Detection irrespective of coil temperature Light barriers operate 290°C without any water cooling High temperature glass reflectors up to 500°C Robust stainless steel housing Challenges On high grade rolling, the exit coil temperature radiated heat leading malfunctioning of signal of existing light barrier Water cooling line provision was not available Furthermore, existing light barrier gets easily disturbed by pollution or steam or alignment is disturbed with shocks Detection was made difficult by the coil temperature combined with the nearby outdoor area, which facilitates steam formation. Solution Reliable coils detection regardless of their temperature, cold or warm, up to 600°C. Retroreflective model with separate electronics Modular design Products and Accessories Light Barriers Robust stainless steel optics 290°C Stainless steel fiber optic cable 290°C (1,2,5,10mtrs) External laser pilot light : for easy adjustment adaptable to HMDs and light barriers 500°C temperature glass reflectors 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: Down Coiler
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