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447 Precision Off-line Bar Counting On Conveyor Lines Made Easy with Computo EVO- An Artificial Vision System

Hot Rolling Mill, HRM, Steel & Rolling Mills

447 Precision Off-line Bar Counting On Conveyor Lines Made Easy with Computo EVO- An Artificial Vision System

Hot Rolling Mill, HRM, Steel & Rolling Mills

Precision Off-line Bar Counting On Conveyor Lines Made Easy with Computo EVO- An Artificial Vision System Smart Radar Sensor for width measurement Hot Rolling Mills About Computo EVO The radar system is based on an artificial vision system which integrates custom built led lighting system for optimal bars identification. Computo system is easily installed and requires no modification of the mill arrangement in most cases. Integration with plant automation is easy and could be made by Ethernet communication of Profibus DP too. Computo Bundle HOW COMPUTO WORKS OFF-LINE The high accuracy distance sensor with radar system- Contactless, inline measurement of slabs, strips, and plates (up to 1600 °C). Accuracy up to ±300 µm even in harsh environments Independent of alloy or metal type. Eliminates radiation hazards and reduces cost. Computo system can count the number of bars in bundles by taking pictures of the ends of the bars in the bundle HMI Computo bundle Suggested Products Related case Studies Slab Detection on Transfer Table Uninterrupted sensor performance on hot / cold slab in high ambient temperature upto 290°C at charging transfer table without any water cooling. Width Confirmation / Camber Detection Precise laser distance sensor with 0.5mm accuracy working on both hot (upto 1300°C) and cold (black with scale) surface rated for high ambient temperature 60°C. Air/ water cooling options available. Temperature-Sensitive Slab Width Measurement: The Role of IR Cameras in Accurate Data Collection Combined software and IR camera data to provide temperature-compensated width measurements. Both width and temperature can be measured simultaneously Get In Touch 9818400356 enquiry@manglamelectricals.com Tower C, 12, Yamuna Marg, Civil Lines, Delhi – 110054 Get In Touch Mobile Number Email Message/Requirements (optional) Page URL Company Name Thank You …

Sinter,Production,And,Ipon,Making.,Steel,Casting.

Temperature monitoring to ensure uniform heating of sinter bed

Iron Making, Steel & Rolling Mills

Temperature monitoring to ensure uniform heating of sinter bed

Iron Making, Steel & Rolling Mills

Home Case Studies Temperature monitoring to ensure uniform heating of sinter bed Temperature monitoring to ensure uniform heating of sinter bed A non-contact thermal imaging camera was used to monitor the temperature profile of the sinter cake and ensure uniform heating. Hot spots could be detected in time and avoid damage to conveyor and subsequent downtime was avoided. 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 Increased efficiency: Precise control of burner section to ensure uniform heating Improved safety level: Hot spot detection to avoid damage to conveyor and subsequent downtime Process visualization: Monitoring sinter caking on a PC Challenges The sintered material of desired chemical composition and grain size is charged into the Blast furnace. Iron ore fines, limestone, waste, scale and slag particles and dolomites are mixed together. As the mixture is baked and the sinter cake moves on the conveyor, it becomes critical to ensure that the sinter is homogenous through the cake. Proper sintering removes unwanted Sulphur and makes down-stream processes efficient in the blast furnace. Solution In order to ensure uniform heating and to monitor the temperature profile of the sinter cake, a non-contact thermal imaging camera was used. The robust and compact design made it ideal for this application. System features included Temperature Range: 150⁰C – 1500⁰C Wide optic lens. 4-20mA output signal Data logging feature Alarm and alert function Rugged outdoor housing: for installing the camera for high ambient temperature environment 80 Hz frame rate for the monitoring of fast thermal processes Optical resolution of 382 x 288 pixels Products and Accessories Thermal Imaging Cooling Jacket Laminar Air Purge USB to Ethernet High Temperature Cables 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 Iron 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

View,Of,Inside,Of,Steel,Reheating,Furnace,With,Gas,Flame

Prevent slab pile up by view inside the RHF

Hot Rolling Mill, Steel & Rolling Mills

Prevent slab pile up by view inside the RHF

Hot Rolling Mill, Steel & Rolling Mills

Home Case Studies Prevent slab pile up by view inside the RHF Prevent slab pile up by view inside the RHF Operator to get inside view of the walking beam furnace. Prevent any slab pile-up leading to loss in production. Visual camera to operate in high ambient temperature to withstand upto 2200 °C. Rugged camera in a stainless housing and complete electronics for safe monitoring of retraction / shutter device to actuate when water supply is accidentally switched off. 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 Profile temperature measurement to ensure quality of rolling and prevent cobble Compare edges temperature and centre to adjust the spray headers/ furnace Measure drop out temperature at exit of furnace even in presence of high oxidation Measure the bottom profile temperature to prevent hook-up / cobble 3Lakhs temperature points scanned Challenges Operator to get inside view of the walking beam furnace Prevent any slab pile-up leading to loss in production Visual camera to operate in high ambient temperature to withstand upto 2200 °C Solution 3 options for housing Rugged camera in a stainless housing and complete electronics for safe monitoring of retraction / shutter device to actuate when water supply is accidentally switched off. 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 Manual rod to check the camber measurement Case Studies Other Solutions in Reheating Furnace 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

Bearingless encoder system MAG withstands permanently extreme environmental conditions in the roll stand

Steel & Rolling Mills

Bearingless encoder system MAG withstands permanently extreme environmental conditions in the roll stand

Steel & Rolling Mills

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

Easy visualization of the weak refractory hot spots

Cement

Easy visualization of the weak refractory hot spots

Cement

Thermal imaging camera was installed to monitor temperature of kiln shell and identify hot spots there. It enables real time temperature measurement. It delivers sharp images and videos, thereby increasing efficiency and safety. Modular system approach saves power. Home Case Studies Easy visualization of the weak refractory hot spots Easy visualization of the weak refractory hot spots 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 Increased efficiency: Scanning of the entire kiln from 60-100mtrs was now feasible. Improved safety level: Automatic hot spot detection could be done hence avoiding costly damage and subsequent downtime Save power: 3nos of analog/ digital output were available to activate the cooling fans Shadow monitoring of Slip rings: Modular system approach that enabled additional thermal camera to be installed for capturing hidden area Challenges The refractory-lined lower part of the kiln reaches temperatures of up to 2,000 C making it prone to refractory damage. Localized hot spots of the kiln shell may occur, that can lead to extensive damage and warp the kiln. Solution In order to enable real time temperature measurement and identify hot spots in the kiln shell, a thermal imaging camera Pi640 from Optris was installed. With a very small measuring VGA and an optical resolution of 640×480 pixels, the PI 640 delivers pin-sharp radiometric pictures and videos in real time.It has a compact design, with a body sized 45x56x90 mm and weight of 269 – 340 g it is ideal to be installed where space is limitedThe wide optic lens enabled continuous scanning of the entire kiln from 60-100mtrs relaying a thermal map to plant operations System features include 4-20Ma output signal Data logging Alarm and alert Temperature range of -20 °C to 900 °C (optional up to 1 500 °C) Spectral range: 8 to 14 µm Frame rate: 32Hz Products and Accessories Thermal Imaging Protective Housing Cooling Jacket Laminar Air purge 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 Cement industry 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

Strip detection after laminar cooling

Hot Rolling Mill

Strip detection after laminar cooling

Hot Rolling Mill

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

2. Temperature Measurement of Caster for Billet | Bloom | Slab

Steel & Rolling Mills, Steel Making

2. Temperature Measurement of Caster for Billet | Bloom | Slab

Steel & Rolling Mills, Steel Making

Thermal imaging camera provides accurate temperature profile of the slab eliminating the need of multiple point temperature measurement from a single sensor. Home Case Studies Temperature Measurement of Caster for Billet Bloom Slab Temperature Measurement of Caster for Billet | Bloom | Slab 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 Consistent metallurgical properties: Scales, water do not impact measurement Energy Saving: Optimized heating pattern can be controlled Homogenize temperature: At discharge uniform temperature distribution across length, breadth and thickness Accurate: Scales have no impact on temperature readings Challenges The customer needed the profile measurement for the slab to ensure uniform heating from edge to edge. It was difficult to install and maintain one single sensor for each billet / bloom. Solution Thermal imaging camera allows simultaneous measurement of multiple objects in different locations Measured temperature profile over the entire metal object Could be easily integrated into 24/7 control and monitoring systems System features included 450-1800°C 768*428 pixels 1µm wavelength 1Khz capture rate 3|4|8 nos of Analog 4-20mA Excel data logging (optional) 3nos of Analog 4-20mA Excel data logging 315C of ambient temperature Process visualization: Accurately gauge metallurgical cooling requirements Low maintenance cost: Multiple point temperature measurement from single sensor Highly durable: IR Camera installed 10m away from heat zone Products and Accessories For Secondary Steel Processing Cooling Jacket High Temperature Cables 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

Incremental heavy-duty encoders defy the most adverse conditions in mining operations to ensure reliable speed control

Crane, Material Handling

Incremental heavy-duty encoders defy the most adverse conditions in mining operations to ensure reliable speed control

Crane, Material Handling

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

Smelting,Metal,In,A,Metallurgical,Plant.,Liquid,Iron,From,The

MAG with large split pulse wheel for improved control accuracy

Crane, Material Handling

MAG with large split pulse wheel for improved control accuracy

Crane, Material Handling

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. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Russia,,Lipetsk,,Novolipetsk,Steel,,Rolling,Mill,2000,,Output,Stands

Special looper encoders withstand the most extreme operating conditions in hot roll stands

Steel & Rolling Mills, Steel Making

Special looper encoders withstand the most extreme operating conditions in hot roll stands

Steel & Rolling Mills, Steel Making

Compact IR thermal imaging camera was installed to provide a temperature map of the bottom shell. The cameral scans the full bottom of the shell giving options to define multiple areas /ROI to get 4-20mA output. Software automatically finds hot spots enable timely preventative maintenance. Home Case Studies Special looper encoders withstand the most extreme operating conditions in hot roll stands Special looper encoders withstand the most extreme operating conditions in hot roll stands Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Subject to high loads from shock, temperature and cooling emulsions Heavy-duty ball bearings with special lubrication Increased lifetime Reduced downtime Loopers in hot rolling mills are working under extremely rough conditions. Challenges Loopers are normally used to control the tension of the metal strip between roll stands. The rotational angle of the looper is measured by a feedback encoder that is exposed to special demands. The setting angle up to only about 45° results in a partial load on the encoder bearings in conjunction with insufficient bearing lubrication. The encoder is subject to high levels of shock and temperature loads as well as oil / cooling emulsions / water at the place of installation. Formerly used standard encoders have not reached the required lifetime. Looper encoder with heavy-duty ball bearings and special lubrication for long lifetime. Solution For this application Johannes Hübner Giessen developed a special looper encoder, which boasts a considerably longer lifetime thanks to especially designed-in features. These contain oversized bearings with the dynamic load rating increased by 40 % as well as a special radial shaft sealing ring with an additional protective lip. To guarantee the best signal quality the bearings are not primarily designed for high speeds, but rather for high shock loads up to 450 g. The min. degree of protection is IP66 / IP67 with an operating temperature up to 100 °C. Products and Accessories Looper Encoder Coupling Connector Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other applications in Steel Making Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

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Injection,Molding,Machines,In,A,Large,Factory.,Department,Of,Italian

Accurate Non-Contact Temperature Measurement during injection molding, extrusion and blow molding

Plastics

Accurate Non-Contact Temperature Measurement during injection molding, extrusion and blow molding

Plastics

Home Case Studies Accurate Non-Contact Temperature Measurement during injection molding extrusion and blow molding Accurate Non-Contact Temperature Measurement during injection molding, extrusion and blow molding Accurate temperature measurement ensures homogenous wall thickness Minimizes risk of expensive ‘injection tool damage’ Provides object actual temperature Challenge Overheating/ underheating results in undesired shrinkage and white-spots Solution Accurate temperature measurement ensures homogenous wall thickness and mold cooling efficiency Solves problem of double shot Provides object actual temperature Minimizes risk of expensive ‘injection tool damage System features include Optical resolution options: 80×80 pixels or 382×288 pixels Temperature range of -20°C to 900°C Products and Accessories Thermal imaging camera for plastics applications 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 Plastics industry 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

Hoist / Drum: Improved operating reliability and positioning accuracy at the ladle crane

Crane, Material Handling

Hoist / Drum: Improved operating reliability and positioning accuracy at the ladle crane

Crane, Material Handling

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

Tank,Pours,Liquid,Metal,At,The,Steel,Mill

Benefits of using a thermal imaging camera in a cast iron foundry

Casting and Forging

Benefits of using a thermal imaging camera in a cast iron foundry

Casting and Forging

Home Case Studies Benefits of using a thermal imaging camera in a cast iron foundry Benefits of using a thermal imaging camera in a cast iron foundry Continuous temperature monitoring Optimum process control achieved resulting in reduced electricity wastage Reduces safety hazard for operator One time investment with no recurring costs Challenges Accurate temperature monitoring is critical to ensure high quality and efficiency of the casting process as the quality of casting is highly dependent on the temperature of the molten metal. Low temperatures result in poor quality of casting whereas too high temperatures results in energy wastage and may cause damage to the ladle refractory. Mostly commonly thermocouples are used to measure temperature by dipping it in the molten metal in the ladle. Although thermocouples can be used to measure the final tapping temperatures after the liquid has been poured into moulds, they cannot measure temperature of the pouring stream. By the dipping approach, the operator needs to manually take the measurement and requires him to be in close proximity. Thermocouples only give temperature readings at specific time points (when dipped). Furthermore, tips need to be continually replaced resulting in ongoing consumables cost. Solution Thermal imaging cameras provide a more accurate alternative to thermocouples by measuring the temperature of the liquid tapping stream as it is being poured into the mould to make the final product. The solution has the following benefits – No alignment issue: Hot spot detector automatically differentiates between slag and hot metal Increases productivity: Non-contact measurement does not interrupt tapping / casting process Provide traceability: Each melt temperature is recorded with image Improved product quality: with precise temperature control No recurring consumable cost: One time investment, with payback in few months. Products and Accessories Thermal Imaging Protective Housing Cooling Jacket Laminar Air purge 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

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