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Critical Assets Preventive Maintenance for Ladle on Crane

Steel & Rolling Mills, Steel Making

Critical Assets Preventive Maintenance for Ladle on Crane

Steel & Rolling Mills, Steel Making

Ladle Refractory Monitoring System using thermal imaging ensures continuous measurement of shell temperature, identifies hot spots and generates alarm when temperatures are exceeded. Costly machine damage is avoided with early detection of weak spots allowing selective repairs Home Case Studies Critical Assets Preventive Maintenance for Ladle on Crane Critical Assets Preventive Maintenance for Ladle on 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 Increased efficiency: Ladle lifetime improvement with early detection allowing for selective repairs as opposed to full lining replacement Improved safety level: Prevents breakouts and reduces risk of damage to personnel & plant equipment Enables Preventive Maintenance: Real time system running 365 / 24/ 7 days, with warning of excessive shell temperature from refractory degradation Avoids unscheduled downtime: Avoids costly machinery damage and days to clean-up mess Challenges Over time, the refractory linings degrade or develop cracks leading to puncturing. As a result, the outer shell of the ladle becomes exposed to excessive temperatures Solution System Features of the Ladle Refractory Monitoring System include Reliable alarm release at defined thresholds Easy hot spot detection 3 cameras to fully capture the ladle from all side + 1 camera from bottom Products and Accessories Thermal Imaging Camera Cooling Jacket Laminar Air purge Protective Housing High Temperature Cables USB to LAN 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

Quality Assurance in Induction Welding in Tube Mill using fast response IR camera / pyrometer

Tubes and Pipes

Quality Assurance in Induction Welding in Tube Mill using fast response IR camera / pyrometer

Tubes and Pipes

Infrared camera or ratio pyrometer are ideally suited for quality assurance in induction welding in tube mill. It offers fast response and ensures optimal seam during the welding process. Being tolerant to dirty environment, it can withstand high temperature and is ideal for hard to access areas. Home Case Studies Quality Assurance in Induction Welding in Tube Mill using fast response IR camera / pyrometer Quality Assurance in Induction Welding in Tube Mill using fast response IR camera / pyrometer 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 c Challenges Ensuring optimal seam during the welding process Solution Temperature Monitoring using Ratio Pyrometer Ratio Pyrometer with temperature Range: 500⁰-1800⁰C Tolerant to dirty environment: 5% FOV coverage is sufficient Withstands high ambient temperature: 250⁰C for optic head /Fibre Optic Separate electronics: Electronic module is sperate. Ideal for hard to access area: Small sensor head dimensions Temperature Monitoring using thermal imaging Products and Accessories Next Generation Pyrometer: Dirt & Steam Resistant, for high ambient environment Thermal Camera 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 Tubes and Pipes 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

Fire Safty of running Sinter on Conveyor Belt

Iron Making, Steel & Rolling Mills

Fire Safty of running Sinter on Conveyor Belt

Iron Making, Steel & Rolling Mills

Thermal imaging cameras can effectively detect any uncooled areas within the coke and identify potential hot spots. Continuous temperature monitoring of the coke on the conveyor ensures rapid response to hot spots thereby protecting the conveyor belt from damage and reduces fire risk from hot inclusions reigniting coke. Home Case Studies Temperature coke wharf Fire Safty of running Sinter on Conveyor Belt 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 Online continuous monitoring of running Sinter Improved safety level: Prevents fire and reduces risk of damage Enables Preventive Maintenance: Real time system running 365 / 24/ 7 days Avoids unscheduled downtime: and costly machinery damage and clean time Challenges Sinter runs on conveyor belt at certain temperature. If sinter reaches very high temperatures it can cause fire at upcoming stage of production At the installation point lot of dust is also present and ambient temperature is high Solution System Features for the prevention of fire in Sinter conveyor: Continuous monitoring of the thermal profile of running Sinter and with real-time temperature data (Analog Output) Reliable alarm release at defined thresholds and snapshot on that event. Easy hot spot detection. Reduced risk of damage to personnel & plant equipment. Camera with water cooled housing, air purge system for harsh environment. Specifications Special Spectral range: 8 – 14 µm. Resolution: 382×288 pixels Frame rate: 80 Hz Signal Output:4-20 mA/ 0-10 V Available interface: USB/optional USB to PoE Products and Accessories Thermal Imaging Camera Water Cooling Jacket 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 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

Metallurgical,Plant,Azovstal,(azov,Steel),In,Mariupol,,Ukraine.,01-06-2017

Condition based monitoring for Tuyeres

Iron Making, Steel & Rolling Mills

Condition based monitoring for Tuyeres

Iron Making, Steel & Rolling Mills

High-resolution infrared camera provided real-time thermographic images unaffected by noise from combustion gases to quickly detect hot spots in the tuyeres and optimize process conditions as needed Home Case Studies Temperature Measurement of the coke for fire safety in the coke wharf-2 Condition based monitoring for Tuyeres 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: Scans the entire tuyeres to check for any refractory break. Improved safety level: Hot spot detection to avoid costly damage and subsequent downtime Challenges During the process of heating iron-ore to make iron, hot air is injected at high temperature at the bottom of the blast furnace by tuyeres. The heated air optimizes the process accelerating the burning of the coke and effectively reduces the coke consumption per ton of iron produced. As smelting temperatures of over 1600⁰C is produced, it becomes critical to carefully monitor refractory temperature for hot spots and blockages.Thermocouples do survive the high heat and high-pressure environment but lifespan of the thermocouple is significantly reduced due to damage to its metal sheath. Furthermore, sudden change in temperature readings due to snorting can result in unreliable thermocouple signals. Solution A high-resolution infrared camera from Optris is ideal for this application. It provides pin-sharp infrared pictures and videos unaffected by noise from combustion gases.The real-time thermographic images prove especially valuable to quickly detect hot spots and optimize process conditions as needed. System features include Temperature range of 50⁰-600⁰C Wide optic lens Alarm and alert PTZ Housing: Pan- Tilt housing Products and Accessories Thermal Imaging Camera Water Cooling Jacket 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

Bucket,Wheel,Excavator.,Reclaimer,Stacker,Continuous,Loading,Delivery,mining

24 Proximity for outdoor application

Infrared sensors, Infrared temperature sensors, Thermal Cameras

24 Proximity for outdoor application

Infrared sensors, Infrared temperature sensors, Thermal Cameras

Proximity for outdoor application Proximity Sensor Efficient operation in outdoor setting Resistant to dirt, dust Insensitive to soiling and wear-free Plastic housing Specifications Sn: 70 mm IP 67 Temp: -25 to +100 °C Supply voltage: 10-55 VDC Cable length: 2,5,10,15,20 m Cable MOC: Silicone cable No. of wires: 2-wire, 3-wire Housing (Ǿ): 80x80x40 Cable conduit protection available (Pg X) Proximity installed for outdoor applications Suggested Products Large Sensing Distance Proximity Inductive Proximity Sensor 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 …

Pinch roll rod detection before laying head

Steel & Rolling Mills

Pinch roll rod detection before laying head

Steel & Rolling Mills

Hot Metal Detector was used for the detection of long product rolling. The sensor’s small spot size is big enough to capture bar fluttering but without sensing crop ends. No water cooling was required as the sensor was provided with a fibre optic cable between the optics and the electronics. Electronics were kept 2m away from the heat zone Home Case Studies Pinch roll rod detection before laying head Pinch roll rod detection before laying head 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 Dual (Hystersis) Threshold: Customer could now create band to control signal on/off (Son and Soff. Avoid false triggering when temperature dropped for short durations due to presence of steam. Maintenance free modular design: Three-piece design (Optics, fiber optic cable, electronics) parts can be each purchased separately. Compact size: Optics are 25mx85mm. Possibility to implement redundancy and shadow mode operations to compare the results. Flexibility for variable response temperature threshold (400C..10000C) as per site: The object temperature can range from 1000C to 18000C. On special request model can start as low as 250⁰C to 600⁰C Standard-function, offset-function, alarm-function and jump-detection 2 free adjustable switching outputs Challenges The existing solution suffered from various problems Oversensing Scanning technology detected hot crops/ tail ends fallen on the track Flickering at water box exit: Bar temperature used to drop from 900⁰C to ~600⁰C with existing solution’s fixed triggered threshold. Expensive maintenance: Water cooling line had to be ON all times to avoid electronics failure. Redundancy not feasible Existing solution had a bulky design therefore it was not feasible to implement dual HMDs. Solution HMD optical sensor is ideal for this application. The sensor’s small spot size is big enough to capture bar fluttering but without sensing crop ends. (Optics 20 has 55mm spot size) No water cooling was required as the sensor was provided with a fibre optic cable between the optics and the electronics. With the FOC system, the sensor can operate at ambient temperatures upto 2900C without any water / air cooling. Electronics were kept 2m away from the heat zone. All components were housed in protective rugged stainless steel for protection against moisture, steam, shock and vibration. Optical filters protected against spurious radiation. Variable Response Temperature threshold could be set as per site requirement from 4000C to 10000C. Note: Other models that start as low as 1000C response temperature are also possible Products and Accessories Compact HMD for TMT bars Flicker free HMD for long and flat rolling Flicker free compact HMD for high ambient environment 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

Zaporozhye,,Ukraine,-,26,November,2008:,Metallurgical,Factory.,Industrial,Processes

Precise Looper Position Feedback

Hot Rolling Mill, HRM, Steel & Rolling Mills

Precise Looper Position Feedback

Hot Rolling Mill, HRM, Steel & Rolling Mills

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

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

Quality Control of Solar Cell Modules

R&D

Quality Control of Solar Cell Modules

R&D

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 Next Generation Infrared Camera for ultra high resolution imaging of electronic circuit boards 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 Current Solution with 0.6x magnification Next Generation Advanced Optics with 2.4x magnification Solution Benefits Combination of multiple optical lens resulting in highest ever magnification level Extreme high resolution to detect over heating on very small components Specifications FOV : 3.5 mm x 4.5 mm Temperature range: -20 °C to 900 °C (optional up to 1 500 °C) Spectral range: 8 to 14 µm Frame rate: up to 125 Hz Products and Accessories Thermal Imaging Camera 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 R&D 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

Width Measurement for Camber detection

CRM, Hot Rolling Mill, Steel & Rolling Mills

Width Measurement for Camber detection

CRM, Hot Rolling Mill, Steel & Rolling Mills

Home Case Studies Width Measurement for Camber detection Width Measurement for Camber detection Contact based length measurement. Inaccurate and manual process was not practical for continuous casting mill. Non-contact laser distance meter to work on hot surface upto 1300°C. 200°C ambient temperature with water cooling. 3nos of digital output and 1nos of Analog (4-20mA). Works on even dark surface (gray slabs). 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 Accurate width measurement for camber detection. Precise measurement : +/-1mm accuracy with 2σ Stainless housing with double walled cooling for ambient temperature upto 200 °C Works on product surface upto 1300 °C Analog and digital outputs Challenges Contact based length measurement Inaccurate and manual process was not practical for continuous casting mill Slab hitting the tunnel furnace refractory causing unplanned breakdown Solution Non-contact laser distance meter to work on hot surface upto 13000C. 200C ambient temperature with water cooling 3nos of digital output and 1nos of Analog (4-20mA) Works on even dark surface (gray slabs) Products and Accessories Light Barriers Technical Specifications Accuracy ± 1mm Repeatability ± 0.3 mm Measuring ranges up to 100 m on natural surfaces Measuring ranges up to 500 m on reflective foil 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 – Hot Rolling Mill 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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488 Visualizing Slab Heat in Tunnel Furnace with Thermal Camera

Hot Rolling Mill, HRM

488 Visualizing Slab Heat in Tunnel Furnace with Thermal Camera

Hot Rolling Mill, HRM

Visualizing Slab Heat in Tunnel Furnace with Thermal Camera Thermal Camera Challenges Needed to measure slab surface temperature at tunnel furnace entry and exit. Solution Employed the short- wavelength thermal camera at tunnel furnace entry and exit Captures accurate measurement data for precise surface temperature analysis of slab Non‑contact sensingin harsh conditions Real‑time data output enabling effective process monitoring and control Continuous full slab coverage using line scanning function Gives multiple output options Specifications Temperature range:450°C to 1800°C Analog o/p : 0/4 – 20 mA Suggested Products Thermal Camera 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 …

Aerial,Panoramic,View,Of,Hydroelectric,Dam,On,River.

Tilt Angle Sensor For Radial Gate Positioning

Power

Tilt Angle Sensor For Radial Gate Positioning

Power

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

Forklift,Handling,Container,Box,Loading,At,The,Docks,With,Truck

Switching accuracy at the crane hoist by compact incremental encoder with electronic over speed switch

Ports and Cranes

Switching accuracy at the crane hoist by compact incremental encoder with electronic over speed switch

Ports and Cranes

The EGS series of electronic overspeed switches from Johannes Huber Giessen are the ideal solution for heavy -duty applications that demand the highest levels of precision and reliability. These devices make it possible to monitor both overspeeds and underspeeds across the complete speed range with utmost precision. Home Case Studies Significantly higher switching accuracy at the crane hoist thanks to compact incremental encoder with additional electronic overspeed switch Higher switching accuracy at the crane hoist by compact incremental encoder with additional electronic overspeed switch Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Modern replacement solution for mechanical overspeed switches Compact design with an incremental output and electronic overspeed switch Pre-programmed switching speed Easy mechanical and electrical exchangeability Before: Tacho generator with attached mechanical overspeed switch for speed measurement and monitoring at the hoist of a RMG crane. Challenges A tacho generator and an additionally attached mechanical overspeed switch are responsible for speed measurements and overspeed monitoring at the hoist. Due to its design the mechanical overspeed switch has a switching tolerance of ± 75 rpm, which leads to inaccuracy at the desired switching point. Moreover, the mechanical overspeed switch only reacts to speeds of 700 rpm and above. The signal quality of the tacho generator does not o er the precision required in today’s world. The customer wished for a replacement solution that corresponds to current state of the art technology. Products and Accessories Speed feedback for auxiliary drives Couplings Adapter Shaft After: Significant more precise speed monitoring by the incremental encoder FG 2 with integrated electronic overspeed switch. Solution Based on the experience gained from previous modernization projects the implemented solution saw the installation of an incremental encoder FG 2 with an integrated electronic overspeed switch (option S). In addition to the incremental position value this compact encoder solution o ers a switching speed set ex works. The electronic overspeed switch provides signifi cantly more accurate overspeed monitoring. The switching speed of 2550 rpm was adopted from the previous solution 1:1. Not only is the overall length now distinctly shorter, this solution requires no changes to the existing mechanical interface. The entire conversion was implemented quickly and easily. Heavy duty programmable overspeed switch Speed feedback for main drives Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills – Roughing Mills View All

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