Lights-out factory - Smart sensors and camera-based solutions
In our industry, the "Lights-out Factory" is basically the equivalent of a self-driving car. In addition, the degree of automation in metallurgical plant and equipment is set to grow further. This can only succeed if the relevant sensors are used to view, hear, and collect data.
In our Learning [Steel] Plant, we rely on smart sensors and thus on the gapless collection of data, on transparency, and on dynamic and self-optimizing solutions that effectively supplement existing equipment in the extremely harsh environment of the metal industry and make them fit for the future.
With X-Pact® Sense, plant owners have a wide range of solutions based on visual, acoustic, and haptic evaluations. Intelligent algorithms process the input data to produce the correct results quickly and effectively, evaluate them in an intelligent manner, and pass them on in a targeted manner to other applications using modern communication standards.
This involves compact units, in which sensor, evaluation, recording, and communication technologies are brought together in one device. The components are designed for use in the harsh environment of a steel mill and satisfy all relevant mechanical and thermal requirements.
X-Pact® Sense sensors and cameras featuring smart logic and SMS group domain know-how give your plant intelligence and open up a range of new possibilities. The process automation system can be expanded on the basis of the new information provided. The production process becomes more efficient and flexible.
Not only that, it is highly energy efficient and requires less maintenance.
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Slag detection with X-Pact® Sense
All in one: sensor, evaluation, recording and communication
Timely, safe and intelligent slag detection, automatic tapping process support, overflow detection at the converter mouth incl. data evaluation and alarm function.
Key features
- Easy integration into existing and new production facilities
- Data exchange with the plant automation system
- Support for the operating personnel
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Benefits
Productivity
- Increased tapping process reliability
- Low maintenance
Quality
- Controlled slag amount
Digitalization
- Intelligent evaluation algorithms
- Web interface
- Connectivity
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Strip center measurement with X-Pact ® Sense hotCAM
Use of a closed-loop algorithm to calculate the strip center line deviation and provides a levelling correction signal for the hot rolling mill stands.
For the different rolling sequences (head, filet, tail end) different control methods are used. Smooth transition between the control actions in the different phases is ensured.
The X-Pact® Sense hotCAM itself is designed against harsh environmental conditions like high strip temperature, fog, steam, dust and vibrations.
The hotCAM continuously takes images of the hot strip or plate. Only the thermal radiation of the hot strip is taken into account.![]()
Key features
- Improved process stability and reduced cobbles in the finishing mill and coiler area due to better strip guidance
- Increased yield due to less cobbles and less roll changes
- Tight strip dimension accuracy for stable thin gauge production down to 0.8 mm
