FROM ORE TO STEEL

SMART SOLUTIONS FOR THE STEEL INDUSTRY

STEEL
A CONNECTION AS HARD AS STEEL
Modern turnkey solutions built with the eyes of our customers – this is
our claim when it comes to secure production processes in industry.
No matter whether high temperatures, fire, dust or vibration: For more
than 50 years, PIEPER brings in the expertise for the development,
production and installation of individual process monitoring solutions.

As a reliable partner, we take care of your individual projects on site –

before during and after installation. A profound knowledge of the
industry is only the beginning. Challenges such as optimum plant
utilization, cost-efficient production, improved planning and logistics
as well as increased safety for both operator and machine find their
answers in our systems.
 WHERE TRADITION MEETS THE MODERN
The steel industry has a long history. Traditional production methods are still used today. But when
economic conditions change, technology is needed to meet them adequately and in a timely manner.
After all, in order to remain competitive, steelworks today must above all avoid the loss of efficiency
and quality. Aging equipment makes this task more difficult.

SINTER PLANT This is where PIEPER comes into the picture:

Networked digital process monitoring systems based on video surveillance ensure a smooth
production chain.
BLAST FURNACE CONVERTER

COKING PLANT

CONTINUOUS CASTING PLANT

HOT GALVANIZING COLD ROLLING MILL HOT ROLLING MILL

 In combination with appropriate management and analysis software and taking into account all
local conditions, the advantages are obvious:

▪ Efficiency: Integration of digital video technology into already existing systems

▪ Overview: Provision of an overall picture of the current production as well as live images for
SINTER PLANT monitoring individual processes
▪ Hazard minimization: Avoidance of cost-intensive production downtimes
▪ Safety: Remote control away from any high temperature or potentially dangerous
BLAST FURNACE CONVERTER
environment
▪ Resource optimization: Predictability of maintenance and repair intervals
▪ Quality: Analysis and evaluation possibilities of material and machine
▪ Flexibility: Use of special camera technology depending on the environment (visual,
COKING PLANT thermographic, sensor-based)
▪ Sustainability: Documentation and logging support

CONTINUOUS CASTING PLANT The result for a modern steel production:

Significant process acceleration through automation

HOT GALVANIZING COLD ROLLING MILL HOT ROLLING MILL

INDUSTRIAL NETWORKS IN THE FUTURE
As a specialist for industrial process monitoring as well as video and security systems, we rely on
modern, future-proof solutions – bringing in 50 years of experience.

▪ Up-to-date: Integration of modern, IP-based solutions into a holistic system

▪ Profitable: Increasing the efficiency and safety of production chains
▪ Individual: Demand-oriented planning and implementation
▪ Forward-looking: Efficient operation and maintenance of network systems
▪ Convenient: Complete support from conception to installation and after-sales support
 INTEGRATION INTO EXISTING NETWORKS
The replacement of analog technologies by IP-based, intercommunicating systems gives
manufacturing companies a decisive competitive advantage: the degree of automation of their
process chain is significantly increased.
KAMERA MONITOR

By integrating digital video technology into existing systems, PIEPER paves the efficient way to
industrial production:

PLC
MODBUS TCP ▪ Integration of modern process monitoring components into existing network systems
PROFINET IO
PROFIBUS DB ▪ Single point of control and monitoring of a production line
KUNDENSPEZ. SDK VMS …
FUNKTION
▪ Extensive evaluation and prevention measures through integration of analysis software
▪ Minimizing risk and error potentials for both operator and machine
IO PERIPHERIE ▪ Significant time, material and cost savings
▪ Improving predictability of maintenance tasks
▪ Optimizing product quality

NVR BEDIENFELD
THE SINTER PLANT
Sinter is considered an important basic material for the production of pig iron, which is made, among
other raw materials, from fine ore and coke in the sinter plant.

Since all materials must have a certain minimum size for further processing in the blast furnace, the
raw materials are baked together by a firing process in the sintering plant. The resulting mass – the
sinter cake – is fed to the blast furnace after further processing through crushers, coolers and sieves.
 OVERVIEW CAMERAS
In process monitoring, which is geared towards detailed inspection and evaluation within a
ORE-COKE-MIXTURE
production chain, visual observation of the entire plant shouldn’t be neglected. For this purpose,
overview cameras are installed at strategic positions that they provide an overall picture of the
current production. The images thus generated are transmitted live to the control center, so that any
imminent malfunctions are detected at an early stage.

IGNITION CAP
In addition to avoiding cost-intensive production downtimes, the environment also benefits
here: a defective filter system can be detected more quickly, for example, as a change in the color of
SINTER-CAKE the exhaust gas often indicates a malfunction. The control center can thus take immediate action
and counteract dangers.
CRUSHER
At the same time, the use of surveillance cameras increases work safety for the specialist personnel
directly working at the plants: The early detection of a malfunction, which the employee on site may
not even be aware of, reduces the risk of an accident to a minimum.

EXHAUST AIR

SINTER / BURDEN
 SINTER PROCESSING / CRUSHER
To ensure the sinter can be fed to the blast furnace after the firing process, it has to be processed
ORE-COKE-MIXTURE
immediately by downstream machines. The caking of the individual raw materials has resulted in a
flat, porous mass of fine ore, coke and other auxiliary materials, which has to be crushed to the
required size. To ensure that it breaks evenly, it is cooled during transport on the conveyer belt.
Consistent temperature distribution is essential for this production step.

IGNITION CAP
The use of visual or thermographic cameras helps the operator to detect deviations quickly. If the
sinter cake breaks irregularly or if an undesired drop in the temperature is measured, partial process
SINTER-CAKE heat can be added again via nozzles located on the underside of the conveyor belt.

CRUSHER

EXHAUST AIR

SINTER / BURDEN
THE COKING PLANT
The heart of a coking plant is the oven battery. Up to 100 closely adjacent furnace chambers are
filled with hard coal via a trolley running on the ceiling. Heating flues located between the chambers
ensure that the coal is continuously heated over 1,000 °C. After the firing process, the glowing coke
is presented into a quenching car and driven to the quenching tower for rapid cooling.
 OVERVIEW CAMERAS
In process monitoring, which is geared towards detailed inspection and evaluation within a
production chain, visual observation of the entire plant shouldn’t be neglected. For this purpose,
overview cameras are installed at strategic positions that they provide an overall picture of the
current production. The images thus generated are transmitted live to the control center, so that any
imminent malfunctions are detected at an early stage.
COAL BUNKER
In addition to avoiding cost-intensive production downtimes, the environment also benefits
here: a defective filter system can be detected more quickly, for example, as a change in the color of
the exhaust gas often indicates a malfunction. The control center can thus take immediate action
and counteract dangers.

CHARGING CAR At the same time, the use of surveillance cameras increases work safety for the specialist personnel
directly working at the plants: The early detection of a malfunction, which the employee on site may
RAM
FURNACE CHAMBER not even be aware of, reduces the risk of an accident to a minimum.

QUENCHING CAR
 MONTORING THE FILLING OPENINGS
One or more furnace probes mounted on the charging car observe the openings on the furnace
roof; thus the level of a single coke oven can be checked at any time. This simplifies and speeds
up the process and at the same time makes it safer for the workers, who no longer have to watch the
level in the immediate vicinity of the hot oven. In addition, the furnace probes continuously check the
openings for possible caking, which makes it difficult to fill the chambers.
COAL BUNKER

CHARGING CAR

RAM
FURNACE CHAMBER

QUENCHING CAR
 QUENCHING CAR
A potential hazard in a coking plant is unevenly slaked coke. If the hot coke is transported on the
quenching car to the cooking ramp, critical hot spots may form. Depending on the requirements,
such embers can be searched by using a visual or thermographic solution – at best a combination
of both.

COAL BUNKER The software-integrated visual cameras are set to send alarms in case of defined color
deviations within the embers. Thermal cameras record and evaluate the temperature of the coke; if
a temperature limit is exceeded, an alarm is sent to the control center.

This way, the operator can react early to a potential danger and, for example, move water canons to
the appropriate place to prevent a fire. The hot spot is cooled and the coke can be transported
CHARGING CAR directly to the blast furnace or coke storage without delay.

RAM
FURNACE CHAMBER

QUENCHING CAR
THE BLAST FURNACE
Iron Ore, lime and coke are the main ingredients for the production of pig iron and are melted in
furnaces up to 75 meters high. To extract the pig iron, the furnaces, which are enclosed in steel
shells and a cooling system, operate at temperatures of up to 2,000 °C. The raw materials are
transported to the furnace head by an inclined elevator and fed into the firing chamber via the top
cover. Every two to three hours, tapping takes place in the casting hall so that the pig iron and slag
can flow off for further processing.
 OVERVIEW CAMERAS
In process monitoring, which is geared towards detailed inspection and evaluation within a
production chain, visual observation of the entire plant shouldn’t be neglected. For this purpose,
overview cameras are installed at strategic positions that they provide an overall picture of the
current production. The images thus generated are transmitted live to the control center, so that any
imminent malfunctions are detected at an early stage.
FURNACE HEAD / BLEEDER

INCLINED ELEVATOR In addition to avoiding cost-intensive production downtimes, the environment also benefits
here: a defective filter system can be detected more quickly, for example, as a change in the color of
the exhaust gas often indicates a malfunction. The control center can thus take immediate action
and counteract dangers.

At the same time, the use of surveillance cameras increases work safety for the specialist personnel
HOT-BLAST STOVES
CASTING HALL
directly working at the plants: The early detection of a malfunction, which the employee on site may
not even be aware of, reduces the risk of an accident to a minimum.
TAP-OFF PLATFORM

SLAG CHANNEL IRON TAPPING

COKE, ORE, LIME TORPEDO CARS

 FEEDING
Iron ore, coke and lime are transported via conveyor belts to the head of the blast furnace and
alternately fed into the combustion chamber. In order to be able to monitor and control the process
in all times, one or more visual cameras are used here, which continuously send live images to
the control center.

FURNACE HEAD / BLEEDER

INCLINED ELEVATOR

HOT-BLAST STOVES
CASTING HALL

TAP-OFF PLATFORM

SLAG CHANNEL IRON TAPPING

COKE, ORE, LIME TORPEDO CARS

 BLEEDER (PRESSURE RELIEF VALVES)
The bleeder is located at the furnace head, which ensures that if the pressure in the blast furnace
builds up too much, it can escape via the flaps. Since an overpressure shouldn’t occur in the normal
course of events, the dampers are monitored by visual cameras for documentation purposes and
are available for recording in case of an incident.

FURNACE HEAD / BLEEDER

INCLINED ELEVATOR

HOT-BLAST STOVES
CASTING HALL

TAP-OFF PLATFORM

SLAG CHANNEL IRON TAPPING

COKE, ORE, LIME TORPEDO CARS

 REFRACTORY LINING – REPAIR & MAINTENANCE
Refractory linings of furnaces have to be replaced from time to time due to the very high continuous
loads. In order to reduce the potential danger and speed up the process, spraying robots are now
used to do this work.

Supported by visual cameras and an external lightning system that allows 360° vision, the robot is
FURNACE HEAD / BLEEDER
controlled by an external operator. This way, the new lining can be applied evenly in a short time and
INCLINED ELEVATOR the furnace can be started up again more quickly.

HOT-BLAST STOVES
CASTING HALL

TAP-OFF PLATFORM

SLAG CHANNEL IRON TAPPING

COKE, ORE, LIME TORPEDO CARS

 SLAG TAPPING
During the firing process in the blast furnace, slag is produced as a by-product in addition to iron.
Since both products are needed separately for further processing, their different physical
characteristics are taken advantage of. Slag, which “floats” on the iron due to its lower density, is
tapped at regular intervals. A visual or thermographic camera is attached to the tapping platform in
order to observe the discharge behavior. In this way, it is possible to monitor the process form a
FURNACE HEAD / BLEEDER
safe distance and without the constant presence of an employee in the immediate vicinity when the
INCLINED ELEVATOR blast furnace needs to be sealed again.

HOT-BLAST STOVES
CASTING HALL

TAP-OFF PLATFORM

SLAG CHANNEL IRON TAPPING

COKE, ORE, LIME TORPEDO CARS

 TORPEDO CARS
The thermographic control of the refractory lining of a torpedo car allows a reliable compliance with
the plant safety. This way, the risks of a breakout of molten metal is reduced to a minimum and the
service life of the lining is significantly increased.

With the support of thermographic monitoring, cost-intensive maintenance work is only necessary at
FURNACE HEAD / BLEEDER
longer intervals. The system designed for continuous operation can provide information on the
INCLINED ELEVATOR condition of a torpedo car at any time.

HOT-BLAST STOVES
CASTING HALL

TAP-OFF PLATFORM

SLAG CHANNEL IRON TAPPING

COKE, ORE, LIME TORPEDO CARS

THE CONVERTER
In secondary metallurgy, up to 400 tons of crude steel can be cooked in a modern converter. In the
first step – the refining – liquid pig iron, steel scrap and slag binder are added to the plant. The
required steel quality is achieved in the further process by adding alloying elements, adjusting the
carbon content and removing accompanying elements. When the crude steel is the poured into
ladles, the resulting slag is retained and the steel is transported to the continuous casting plant.
 OVERVIEW CAMERAS
In process monitoring, which is geared towards detailed inspection and evaluation within a
production chain, visual observation of the entire plant shouldn’t be neglected. For this purpose,
overview cameras are installed at strategic positions that they provide an overall picture of the
current production. The images thus generated are transmitted live to the control center, so that any
imminent malfunctions are detected at an early stage.
LADLE
In addition to avoiding cost-intensive production downtimes, the environment also benefits
here: a defective filter system can be detected more quickly, for example, as a change in the color of
the exhaust gas often indicates a malfunction. The control center can thus take immediate action
CONVERTER and counteract dangers.

At the same time, the use of surveillance cameras increases work safety for the specialist personnel
directly working at the plants: The early detection of a malfunction, which the employee on site may
not even be aware of, reduces the risk of an accident to a minimum.

OXYGEN SUPPLY
 LEVEL DETECTION / SLAG DETECTION
The demands on the degree of purity of steel are continuously increasing. The thermographic or
visual monitoring of the transfer of pig iron into a converter significantly facilitates the detection of
slag particles – thanks to the different radiation characteristics of slag and pig iron at the same
temperature.

LADLE

CONVERTER

OXYGEN SUPPLY
 LADLE INSPECTION
A ladle, which permanently transports liquid crude steel from the converter to the continuous casting
furnace, is subject to high material requirements; it must be serviced and repaired frequently.
Thermographic condition monitoring of the ladle helps the operator to determine maintenance
intervals precisely.

In addition to strain and wear of the refractory lining, dangerous hot spots are also detected
thermographically in time, before the ladle can break.
LADLE
Without the support of cameras, the operator has to estimate the maintenance and repair interval and,
in order to avoid accidents, take a ladle out of operation at appropriately short intervals, which leads to
CONVERTER
inefficient production times.

OXYGEN SUPPLY
 MAINTENANCE AND REPAIR OF LADLES
Due to the high heat load, casting ladles must be regularly maintained and repaired. Usually robots
are used for this purpose, which ensure that the refractory lining is sprayed out evenly. For quality
assurance of the ladle condition, a furnace probe is used to monitor the process in detail.

If repairs are necessary, the refractory lining must be replaced. In order to reduce the potential
danger and speed up the process, spraying robots are now used to do this work.

LADLE Supported by visual cameras and an external lightning system that allows 360° vision, the robot is
controlled by an external operator. This way, the new lining can be applied evenly in a short time and
the ladle can be used again more quickly.
CONVERTER

LADLE

OXYGEN SUPPLY
 POSITION MONITORING „SAND FILLING“
Stopper ladles are often used in steel casting, which have a slide on the underside to discharge liquid
crude steel into the continuous casting furnace. These ladles have to be filled with a certain amount of
sand again and again before filling to prevent the slider from sticking to the lower part of the ladle due
to the crude steel and making it impossible to open it.

However, if too much sand is used, it solidifies and the slide valve must be opened manually. This not
only causes delays, but also poses a great risk of accidents when working on a hot, filled ladle.

By using a furnace probe to monitor the level of sand, delays are reduced and potential hazards
are minimized.

LADLE
 VACUUM FURNACE
After the crude steel leaves the converter, it can optionally be further treated in a vacuum furnace to
increase the material quality. In this process, gases present in the crude steel, such as sulfur and
phosphorus, are dissolved or alloys are added.

Depending on the procedure used, cameras or furnace probes are used at the filling openings to
give an overview.

VACUUM FURNACE

LADLE
THE CONTINUOUS CASTING PLANT
In the continuous casting plant, the crude steel is given its first shape. The liquid product is poured
via the ladle turret into the tundish where it is fed via the mould to the strand. Depending on the
casting mould, rectangular slabs and billets or round bars are produced. As the plant is a continuous
casting process, the steel is fed through a cross and/or slitting line at the roller table. A marking
machine ensures clear identification with regard to steel quality and the planned further processing.
 OVERVIEW CAMERAS
In process monitoring, which is geared towards detailed inspection and evaluation within a
production chain, visual observation of the entire plant shouldn’t be neglected. For this purpose,
overview cameras are installed at strategic positions that they provide an overall picture of the
current production. The images thus generated are transmitted live to the control center, so that any
imminent malfunctions are detected at an early stage.

In addition to avoiding cost-intensive production downtimes, the environment also benefits

here: a defective filter system can be detected more quickly, for example, as a change in the color of
the exhaust gas often indicates a malfunction. The control center can thus take immediate action
TUNDISH and counteract dangers.
MOULD
LADLE TURRET
At the same time, the use of surveillance cameras increases work safety for the specialist personnel
directly working at the plants: The early detection of a malfunction, which the employee on site may
not even be aware of, reduces the risk of an accident to a minimum.

SLABS

STRAND

FLAME CUTTER
 OVERVIEW CAMERAS LADLE TURRET
In addition to the general overview of the entire plant, visual cameras are used to monitor the
movements of the ladle turret and the correct position of the ladles. Just as with the observation
of the entire plant, the cameras can be used to detect imminent malfunctions at an early stage.

TUNDISH

MOULD
LADLE TURRET

SLABS

STRAND

FLAME CUTTER
 TUNDISH
To prevent the molten steel from reacting with the oxygen in the air and to prevent undesired
inflammations, casting powder is added to the tundish at regular intervals. This produces slag, which
serves as a lubricant for the mould on the one hand, but can also absorb any remaining impurities
form the steel on the other. Visual cameras support this process and permanently show the filling
level as well as the position of the ladle slide to avoid an interruption of the casting process

TUNDISH

MOULD
LADLE TURRET

SLABS

STRAND

FLAME CUTTER
 STRAND
Thermographic monitoring can provide early indications of possible strand defects, such as cracks
or local leakage of liquid steel.

With a thermographic system for process monitoring an control in continuous casting, both product
quality and energy consumption can be significantly optimized. For this purpose, thermal
imaging cameras monitor the forming and cooling process of the steel strands and control the heat
distribution during this process. The information is passed on to software that assesses the heat flow
and automatically readjusts it if necessary. This ensures an even cooling, which makes a major
contribution to the quality of steel. Furthermore, only the amount of energy that is actually required is
TUNDISH fed into the continuous casting process.
MOULD
LADLE TURRET

SLABS

STRAND

FLAME CUTTER
 FLAME CUTTER / DEBURRING
After cutting the slabs to the desired length, undesirable burrs (edges) can occur at the cut points,
which are then removed with the help of a deburring machine. Visual cameras support the process
monitoring.

The process can be monitored with the help of visual cameras. It is also possible to use
thermographic cameras, which observe and evaluate the cut surfaces on the slabs in detail.

TUNDISH

MOULD
LADLE TURRET

SLABS

STRAND

FLAME CUTTER
 DISCHARGE CONVEYOR
As a final process, the finished cut slabs are marked with batch / identification numbers. For this
purpose a marking machine provides the slab with a punched number at the end of the long side. By
means of a visual camera the correct numbering can be checked as well as the slab removal of
the discharge conveyor is monitored. In most cases, the slab is lifted off the belt by a crane and
temporarily stored until further processing.

TUNDISH

MOULD
LADLE TURRET

SLABS

STRAND

FLAME CUTTER
THE HOT ROLLING MILL
The hot rolling mill produces long or wide flat products. For this purpose, the steel is first heated in a
walking beam, pusher-type or rotary hearth furnace to temperatures of up to 1,260 °C and freed
from scale. The product is then transported by a roller conveyor through a rolling mill, where it is
formed into steel sheets, rails or wire, for example. In flat steel processing, the sheet is then wound
up in coilers and transported to a cold rolling mill for further processing.
 OVERVIEW CAMERAS
In process monitoring, which is geared towards detailed inspection and evaluation within a
production chain, visual observation of the entire plant shouldn’t be neglected. For this purpose,
overview cameras are installed at strategic positions that they provide an overall picture of the
current production. The images thus generated are transmitted live to the control center, so that any
imminent malfunctions are detected at an early stage.

SLAB STORAGE In addition to avoiding cost-intensive production downtimes, the environment also benefits
here: a defective filter system can be detected more quickly, for example, as a change in the color of
the exhaust gas often indicates a malfunction. The control center can thus take immediate action
and counteract dangers.
HEATING FURNACE SCALE BREAKER ROUGHING MILL

At the same time, the use of surveillance cameras increases work safety for the specialist personnel
directly working at the plants: The early detection of a malfunction, which the employee on site may
not even be aware of, reduces the risk of an accident to a minimum.

COOLING ZONE FINISHING MILL SCALE BREAKER CROP SHEAR

DOWNCOILER
 SLAB STORAGE / BAR CODE RECORDING
For a general overview and control, the slab stock is often monitored by means of visual cameras.
Furthermore, a general surveillance of the warehouse also serves to increase work safety. Potential
hazards that may be difficult for individual employees to detect on site are recognized quicker by the
control center, which has a better overall view; accidents can be avoided.

In addition, in some cases the products are provided with barcodes instead of punch marks, which
SLAB STORAGE provide indication regarding further processing, length, alloy etc. of the slab. The barcodes are
scanned and stored before being loaded into the walking beam or pusher-type furnace. Depending on
the requirements, this also serves as a part of a complete documentation of the entire production
process.
HEATING FURNACE SCALE BREAKER ROUGHING MILL

COOLING ZONE FINISHING MILL SCALE BREAKER CROP SHEAR

DOWNCOILER
 HEATING FURNACE
In a walking beam or pusher-type furnace the slabs are moved continuously: from the charging
device the steel is fed to the furnace by a charging system. In a walking beam furnace this is done by
individual, parallel arranged beams lifting the slab by an upward movement and transport it
horizontally a certain distance, in order to then put the slab back on the furnace bottom. This is
repeated in a kind of “furnace route” up to the removal device.

SLAB STORAGE To avoid the slabs getting wedged during their transport in the oven, furnace probes monitor the
inside. This way, the operator can precisely control where the steel is placed again or when a new
slab can be fed into the furnace.

HEATING FURNACE SCALE BREAKER ROUGHING MILL

COOLING ZONE FINISHING MILL SCALE BREAKER CROP SHEAR

DOWNCOILER
 FINISHING MILL
After heating the steel, it is transported through several rolls and thus reduced to a desired thickness.
Between the individual rolling processes, the surface of the hot strip can be monitored by visual
cameras to obtain information on the surface quality.

Probably the most important camera position is at the point where the hot strip has passed the last
roll, before it is wound up into a coil. If defects are detected during the visual material testing, it’s
SLAB STORAGE possible that the strip is returned to the steel production or – in case of minor defects – its quality is
devaluated and it is classified as construction steel, for example.

HEATING FURNACE SCALE BREAKER ROUGHING MILL

COOLING ZONE FINISHING MILL SCALE BREAKER CROP SHEAR

DOWNCOILER
 COILER
After the last rolling pass, the hot strip is routed through a cooling bed and the wound into a coil. The
coils are then bound and marked according to their intended use.

This process can also be optimally monitored and documented by accompanying visual
cameras.

SLAB STORAGE

HEATING FURNACE SCALE BREAKER ROUGHING MILL

COOLING ZONE FINISHING MILL SCALE BREAKER CROP SHEAR

DOWNCOILER
THE COLD ROLLING MILL
In the cold rolling mill the steel strip is reduced to thicknesses between 0.25 and 3 millimeters. To this
end, the strip is first freed from any scale still adhering in the pickling line. The steel is then rewound
into coils and heated in the bell-type annealing furnace. During the actual rolling process, the steel is
then given its final material properties. The cold strip is then automatically slit longitudinally and/or
transversely in the slitting line before being rolled back into coils for shipping.
 OVERVIEW CAMERAS
In process monitoring, which is geared towards detailed inspection and evaluation within a
production chain, visual observation of the entire plant shouldn’t be neglected. For this purpose,
overview cameras are installed at strategic positions that they provide an overall picture of the
current production. The images thus generated are transmitted live to the control center, so that any
imminent malfunctions are detected at an early stage.
DECOILER END SHEAR WELDING MACHINE PICKLING LINE CLEANING & BELT DRYER

In addition to avoiding cost-intensive production downtimes, the environment also benefits

here: a defective filter system can be detected more quickly, for example, as a change in the color of
the exhaust gas often indicates a malfunction. The control center can thus take immediate action
and counteract dangers.

At the same time, the use of surveillance cameras increases work safety for the specialist personnel
directly working at the plants: The early detection of a malfunction, which the employee on site may
ANNEALING FURNACE COILER TANDEM MILL SIDE-TRIMMER
not even be aware of, reduces the risk of an accident to a minimum.

COILER SKIN PASS MILL INSPECTION LINE DECOILER

LOOPING PIT
 PRE-INSPECTION INLET AREA CONTINUOUS PICKLING LINE
In order to exclude possible material defects, a visual pre-control of the material is already
carried out in the inlet area of the continuous pickling line when the coils are unwound. This important
quality assurance process can be supported by visual cameras.

When uncoiling, the ends of each coil are first cut off with cropping shears in order to obtain uniform
DECOILER END SHEAR WELDING MACHINE PICKLING LINE CLEANING & BELT DRYER end edges. The product is then joined together in the welding machine to form an endless strip. The
faultless execution of the welding is checked with the support of visual cameras.

ANNEALING FURNACE COILER TANDEM MILL SIDE-TRIMMER

COILER SKIN PASS MILL INSPECTION LINE DECOILER

LOOPING PIT
 QUALITY ASSURANCE CONTINUOUS PICKLING
After removal of the oxide layer (scale), rinsing and drying of the strip, another visual material
testing is carried out for quality assurance, which can be supported by visual cameras.

The trimming cut, which removes protruding edges of the strip before it enters the tandem mill, is
also monitored with the aid of visual cameras. This simplifies the manual correction of the strip
DECOILER END SHEAR WELDING MACHINE PICKLING LINE CLEANING & BELT DRYER run for the operator before it’s fed to the tandem mill, and thus to the first rolling process.

ANNEALING FURNACE COILER TANDEM MILL SIDE-TRIMMER

COILER SKIN PASS MILL INSPECTION LINE DECOILER

LOOPING PIT
 QUALITY ASSURANCE ROLLING MILLS
In both a tandem mill and a skin pass mill, the endless strip is guided through several rolls arranged
in a row. In these processes the cold strip is given the required properties such as thickness or
surface finish, with the mill trains being adjustable to customer requirements.

Since the rolls are generally exposed to high levels of heat and vibration, there’s a certain error
DECOILER END SHEAR WELDING MACHINE PICKLING LINE CLEANING & BELT DRYER potential on rolls and/or the material. To ensure that this is noticed and remedied as quickly as
possible, the rolling processes are monitored by visual cameras.

In addition to a visual inspection, the strip can also be monitored with special line scan cameras for
quality assurance purposes. Although the installation is more cost-intensive, it can make sense if the
material is subject to high demands, since those special-purpose cameras offer the advantage of
detecting irregularities in the material at a very high strip running speed.

ANNEALING FURNACE COILER TANDEM MILL SIDE-TRIMMER

COILER SKIN PASS MILL INSPECTION LINE DECOILER

LOOPING PIT
 LOOPING PIT / STRIP ACCUMULATOR
Strip accumulators or looping pits are often used in cold rolling mills. Since the strip speed can be
very high and the different strips are rewound into coils after splitting, such devices for length
compensation are required to avoid material jams.

Visual cameras are used to check that the sheet metal, which is now very thin as a result of
DECOILER END SHEAR WELDING MACHINE PICKLING LINE CLEANING & BELT DRYER processing, doesn’t tilt or break off, thus endangering the continuous production process.

ANNEALING FURNACE COILER TANDEM MILL SIDE-TRIMMER

COILER SKIN PASS MILL INSPECTION LINE DECOILER

LOOPING PIT
 LOADING THE COILS
Visual cameras can be used to survey the finished coils. These give a general overview of the
storage situation and are also used to monitor the correct loading for further transport.

DECOILER END SHEAR WELDING MACHINE PICKLING LINE CLEANING & BELT DRYER

ANNEALING FURNACE COILER TANDEM MILL SIDE-TRIMMER

COILER SKIN PASS MILL INSPECTION LINE DECOILER

LOOPING PIT
THE HOT GALVANIZING
Hot galvanizing is used to protect steel from the negative climatic effects and thus corrosion for as
long as possible and without maintenance. In strip galvanizing, the coils are unwound and joined into
an endless strip using a welding machine. After the sheet has been heated in a continuous annealing
furnace, the actual zinc treatment takes place in a melting bath. In this production step, strip speeds
of up to 220 meters per minute are reached before the steel strip is wound back into coils.
 ENTRY LOOPER ANNEALING FURNACE OVERVIEW CAMERAS
In process monitoring, which is geared towards detailed inspection and evaluation within a
production chain, visual observation of the entire plant shouldn’t be neglected. For this purpose,
overview cameras are installed at strategic positions that they provide an overall picture of the
current production. The images thus generated are transmitted live to the control center, so that any
imminent malfunctions are detected at an early stage.

In addition to avoiding cost-intensive production downtimes, the environment also benefits

here: a defective filter system can be detected more quickly, for example, as a change in the color of
CLEANING the exhaust gas often indicates a malfunction. The control center can thus take immediate action
and counteract dangers.

DECOILER WELDING MACHINE At the same time, the use of surveillance cameras increases work safety for the specialist personnel
directly working at the plants: The early detection of a malfunction, which the employee on site may
not even be aware of, reduces the risk of an accident to a minimum.

INSPECTION LINE
COOLING TOWER

COILER END SHEAR EXIT-SIDE LOOPER

ZINC POT INCL.

FURNACE NOZZLE
 ENTRY LOOPER ANNEALING FURNACE PRE-CONTROL / WELDING MACHINE
Already during uncoiling, the strip is checked for obvious defects with the support of visual cameras.

The product is then joined together in the welding machine to form an endless strip. The faultless
execution is as well monitored by visual cameras.

CLEANING

DECOILER WELDING MACHINE

INSPECTION LINE
COOLING TOWER

COILER END SHEAR EXIT-SIDE LOOPER

ZINC POT INCL.

FURNACE NOZZLE
 ENTRY LOOPER ANNEALING FURNACE ENTRY AND EXIT-SIDE LOOPER
The entry and exit-side looper are used to store the strip during the welding process and for the
cutting machine before the galvanized product is rewound into coils. Visual cameras are used to
check that the sheet metal is not tilted or torn off, thus endangering the continuous production
process.

CLEANING

DECOILER WELDING MACHINE

INSPECTION LINE
COOLING TOWER

COILER END SHEAR EXIT-SIDE LOOPER

ZINC POT INCL.

FURNACE NOZZLE
 ENTRY LOOPER ANNEALING FURNACE ANNEALING FURNACE
Before the steel can bond with the zinc coating, it is heated in an annealing furnace to approx. 450 °C
to 650 °C. In this process, furnace probes are used to continuously monitor the strip position. In
addition, due to the poor lightning conditions, external lightning is used, which is either already
integrated in a camera probe or is placed separately in the furnace as a explicit light probe.

CLEANING

DECOILER WELDING MACHINE

INSPECTION LINE
COOLING TOWER

COILER END SHEAR EXIT-SIDE LOOPER

ZINC POT INCL.

FURNACE NOZZLE
 ENTRY LOOPER ANNEALING FURNACE GALVANIZING BATH
The strip is fed into the galvanizing bath via a lock, the so-called nozzle. To allow the steel to bond
with the zinc, the material is heated to a temperature comparable of the zinc bath under inert gas and
vacuum.

Since slag can be generated during this process, the strip inlet is monitored by special furnace
probes. As with the annealing furnace, the lightning conditions here are also very poor, so that
external lightning must be used.

CLEANING

DECOILER WELDING MACHINE

INSPECTION LINE
COOLING TOWER

COILER END SHEAR EXIT-SIDE LOOPER

ZINC POT INCL.

FURNACE NOZZLE
 ENTRY LOOPER ANNEALING FURNACE INSPECTION
After leaving the zinc bath, a first surface inspection is carried out using visual cameras. After the
coat thickness measurement, the strip is then passed over inspection tables where employees carry
out a visual inspection; the process can also be monitored with visual cameras to support quality
assurance.

CLEANING

DECOILER WELDING MACHINE

INSPECTION LINE
COOLING TOWER

COILER END SHEAR EXIT-SIDE LOOPER

ZINC POT INCL.

FURNACE NOZZLE
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