METAL AND STEEL INDUSTRY METAL FORMING AND FINISHING PROCESS GIVING THE FINAL SHAPE AND TOUCH – PRECISION HOLDS ALL THE ACES. I N D U S T R Y G U I D E METAL AND STEEL INDUSTRY TABLE OF CONTENTS 2 M e t a l a n d S t e e l I n d u S t r y | S I C K 8018922/2015-10-19 Subject to change without notice TABLE OF CONTENTS Tasks Tasks in the metal and steel industry 4 Applications in focus The application graphics shown are not binding, they are no substitute for the need to seek expert technical advice. Continuous casting 6 Hot rolling process 24 Strip processing 40 Material handling processes 52 Products Product overview 74 General information Company 98 Industries 10 SICK LifeTime Services 102 Versatile product range for industrial automation 104 Industrial communication and device integration 114 Services 15 8018922/2015-10-19 M e t a l a n d S t e e l I n d u S t r y | S I C K 3 Subject to change without notice METAL AND STEEL INDUSTRY TASKS IN THE METAL AND STEEL INDUSTRY At the end, the quality has to be right. To achieve this, some things needs to be observed. This includes the correct position and alignment of semi- fnished and fnished products on roller tables and the optimal distance between fnished products in order to avoid damage. Flexible processes and interactions between humans and machines require safety technolo- gy. Protective facilities are necessary and not only secure danger zones but also optimize production. Time is money – this also applies here. Monitoring the fow and dosing of bulk materials optimizes the throughput and reduces maintenance times. The regulations for emissions monito- ring and data transmission to the authorities are becoming increasingly more; this includes the steel industry. SICK delivers sensor solutions for almost every application so that reliable products are delivered to cus- tomers in the end. Security and protection Quality control Positioning It‘s not just the protection of people that The product quality has to be consistent- The encoder, laser scanner, distance is important. Equally important are the ly ensured in the production chain. and presence sensors from SICK make protection of the plant and its machi- Solutions from SICK ensure that the re- the highly precise alignment and po- nes from damage and loss. SICK offers quired quality level of fnished products sitioning of semi-fnished and fnished solutions for collision protection, access is achieved – from measuring the sheet products easier ‒ even for ladle cars, control in risk zones and accident thickness to galvanization, from profling transfer cars, industrial cranes, torpedo prevention within and outside of the and adjustment to warpage detection. ladles. The sensors are available in production building. different designs and with different interfaces. 4 M e t a l a n d S t e e l I n d u S t r y | S I C K 8018922/2015-10-19 8018922/2015-10-19 M e t a l a n d S t e e l I n d u S t r y | S I C K Subject to change without notice Subject to change without notice TASKS IN THE METAL AND STEEL INDUSTRY Emission monitoring Monitoring and checking Material fow optimization Measurement systems either check to Sensors from SICK not only assist in Laser scanners measure the volume see if emissions standards are reached complying with the emission limit val- fow on conveyor belts. Encoder and and complied with or only report limit ues, but also provide reliable data as presence sensors control the dosing violations. Operators in steel mills verifcation for the monitoring autho- process. Level sensors monitor silo con- always trust the expertise of SICK when rity. In addition, remote maintenance tents and material discharge hoppers. choosing appropriate solutions for dust, systems from SICK provide measuring Even the materials management bene- gas fow and exhaust measurement. convenience in daily operation and redu- fts from sensor technology from SICK: ce maintenance costs. the production effciency increases. M e t a l a n d S t e e l I n d u S t r y | S I C K 8018922/2015-10-19 8018922/2015-10-19 M e t a l a n d S t e e l I n d u S t r y | S I C K 5 Subject to change without notice Subject to change without notice applications in focus CONTINUOUS CASTING 6 M e t a l a n d S t e e l I n d u S t r y | S I C K 8018922/2015-10-19 Subject to change without notice CONTINUOUS CASTING applications in focus Continuous casting Focus 1 8 Cooling Water Focus 2 10 Oxygen Torches/Cutters Focus 3 12 Rolling beds, walking beam beds, process machines Focus 4 18 Slab and billet storage Focus 5 20 Conveyor system and rolling bed 8018922/2015-10-19 M e t a l a n d S t e e l I n d u S t r y | S I C K 7 Subject to change without notice Focus 1: Cooling Water CONTINUOUS CASTING 1 Monitoring level and pressure of cooling water during continuous casting Continuous casting machines and equipment require constant monitoring of cooling water, hydraulic fuids and coolants’ levels and pressures. Robust sensors are ideal for these level and pressure monitoring tasks. A pressure switch offers various programmable switching functionalities and up to 3 outputs in a single device. A level sensor LFP Inox g p. 93 measures independently of installation PBT g p. 96 conditions. It accurately measures, even when liquid properties change. Addition- ally, there are no mechanical or moving parts to wear, offering continuous reli- ability for the plant’s staff. 8 M e t a l a n d S t e e l I n d u S t r y | S I C K 8018922/2015-10-19 8018922/2015-10-19 M e t a l a n d S t e e l I n d u S t r y | S I C K Subject to change without notice Subject to change without notice Focus 1: Cooling Water CONTINUOUS CASTING 1 M e t a l a n d S t e e l I n d u S t r y | S I C K 8018922/2015-10-19 8018922/2015-10-19 M e t a l a n d S t e e l I n d u S t r y | S I C K 9 Subject to change without notice Subject to change without notice Focus 2: Oxygen torches/Cutters CONTINUOUS CASTING 1 Positioning of the oxygen cutting torch during continuous casting Positioning the cutting torch during the continuous casting process is an important step in guaranteeing that each object is precisely cut to length. An encoder and presence detection sensor enable accurate positioning of the cut- ter as the hot steel is being extruded. While the photoelectric switch detects the object’s presence, the encoder can be programmed to accommodate any DS50 g p. 87 WS/WE45 g p. 77 value to 65,536 pulses per revolution - DFS60 g p. 82 something no other encoder can do. It includes a revolutionary design and a metal code disc that provides a high temperature tolerance – an undeniable requirement for this task. 2 Measuring length and speed of slabs during casting Knowing the speed and length of steel to optimize subsequent processes. This slabs is important information for the linear sensor accurately measures at correct alignment of oxygen torches and fast speeds (80 m per second) and has mechanical cutters after the casting been successfully tested on hot material process. A contactless OLV linear mea- surfaces. This permanently calibrated, surement sensor measures both length maintenance-free measuring device and speed of the moving object in order helps optimize the steel casting process. This graphic is not presented in the overview. OLV g p. 90 10 M e t a l a n d S t e e l I n d u S t r y | S I C K 8018922/2015-10-19 8018922/2015-10-19 M e t a l a n d S t e e l I n d u S t r y | S I C K Subject to change without notice Subject to change without notice