The blast furnace skip hoist is protected against overspeed on the motor side by a mechanical overspeed switch with integrated speed increasing gear. The universal encoder system U-ONE® is to replace the outdated sensor systems on both the motor and drum sides. Thanks to its modular design it is possible to adapt the system to meet all of the customer requirements. Direct attachment of the basic unit eliminates mechanical inaccuracies resulting from gearbox backlash and supports improved control response.
Higher control accuracy in hot rolling mill due to direct encoder attachment
Pilger mill in tube rolling mills - hot and cold pipe detection
- No mechanical play because solution requires no transfer gearbox or additional couplings
- Directly attachable compact U-ONE basic unit
- EMI safe signal transmission via fiber optic cable
- Improved material quality due to higher control accuracy
Before: The assembly of encoder and mechanical cam limit switches with transfer gearbox and additional couplings produces control inaccuracies cause of mechanical play.
Challenges
- Side guides are used to centre the metal strips upstream of the roll stands. In some cases, mechanical cam limit switches and / or absolute encoders are still used for position detection and control. Attachment to the available shaft end of the drive is a widespread solution. To improve control accuracy and, as a consequence, the quality of the material the customer desires a directly mounted, compact solution without a downstream transfer gearbox (gear backlash). The same demands apply to adjusting the screw downs for thickness control.
Modular U-ONE-System with directly attachable basic unit creates greater control accuracy.
Solution
- The advantage of the modular U-ONE® system from Johannes Hübner Giessen is that just the universal basic device is mounted to the side-guide, while the functional modules are housed externally in the switchboard. A fiber optic cable is used to achieve the EMI safe connection, a solution that offers considerable savings with regard to cabling time and costs. The system is programmed via a central USB interface. The system is easily extended with the series (side-by-side) plug-in function modules in conjunction with the low-cost of spare parts.
Products and Accessories
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
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