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    SWOp CaseStudy EN

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    ThyssenKrupp Steel Europe achieved cost savings and eliminated scrap by installing EMG-BREIMO and EMG-SWOp systems to optimize strip width during production. The systems measure strip width changes, predict contractions based on production data, and minimize unnecessary trimming. This eliminated about 950 tons of scrap per year, saving over the cost of the systems in under 6 months. The systems also improved production quality monitoring and allowed safer operations with reduced material usage.

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    SWOp CaseStudy EN

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    ThyssenKrupp Steel Europe achieved cost savings and eliminated scrap by installing EMG-BREIMO and EMG-SWOp systems to optimize strip width during production. The systems measure strip width changes, predict contractions based on production data, and minimize unnecessary trimming. This eliminated about 950 tons of scrap per year, saving over the cost of the systems in under 6 months. The systems also improved production quality monitoring and allowed safer operations with reduced material usage.

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    SWOp_CaseStudy_EN

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    ThyssenKrupp Steel Europe achieved cost savings and eliminated scrap by installing EMG-BREIMO and EMG-SWOp systems to optimize strip width during production. The systems measure strip width changes, predict contractions based on production data, and minimize unnecessary trimming. This eliminated about 950 tons of scrap per year, saving over the cost of the systems in under 6 months. The systems also improved production quality monitoring and allowed safer operations with reduced material usage.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    51 views2 pages

    SWOp CaseStudy EN

    Uploaded by

    Alpha
    ThyssenKrupp Steel Europe achieved cost savings and eliminated scrap by installing EMG-BREIMO and EMG-SWOp systems to optimize strip width during production. The systems measure strip width changes, predict contractions based on production data, and minimize unnecessary trimming. This eliminated about 950 tons of scrap per year, saving over the cost of the systems in under 6 months. The systems also improved production quality monitoring and allowed safer operations with reduced material usage.

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    of 2

    Mission: Save costs

    ThyssenKrupp Steel Europe achieved more efficient processes,


    saved costly resources and eliminated scrap
    through the use of EMG-BREIMO and EMG-SWOp

    ThyssenKrupp Steel Europe AG, The challenge cooperation between ThyssenKrupp


    location Dortmund, Germany During the production process the strip Steel Europe and EMG has developed.
    shows a constricting behaviour due to The clear defini­tion of the problem by
    ThyssenKrupp Steel Europe AG is among thermal and mechanical treatment – ThyssenKrupp Steel Europe and the
    the world‘s leading producers of premium it shrinks depending on the quality of technical implementation by EMG have
    flat carbon steel. 80 percent of the cold steel, the strip width and strip thickness. resulted in considerable success in a
    rolled products at Thyssen, representing To compensate for this behaviour, the short time. As Jochen Fryn, EMG‘s sales
    more than 4.8 million tons per year, are source material is ordered with a safety manager responsible for the Dortmund
    additionally surface finished in one way margin. This is measured in the way location, explained regarding hot-dip
    or another. Thus, the company pursues that even at maximum constriction, the galvanizing line 8: „In order to reach
    the constantly growing demand for finished strip is still wide enough to be a solution, we first had to learn more
    increasingly higher quality materials. safely trimmed. This rather un­necessary about the processes and procedures for
    trimming cut likewise runs through all the equipment. It was thus important
    In its Dortmund location ThyssenKrupp production steps in hot-dip galvanizing. to precisely measure the changes in the
    Steel Europe operates a cold rolling mill It is pickled, rolled and also galvanized, strip width, and in the second step be
    in which high-quality hot-dip galvanized but accrues at the end of the production able to predict the constrictions based
    and electrogalvanized thin sheet is chain as a „finished“ scrap. on these measurements. The next step
    produced. Hot-dip coating line 8 (FBA 8) towards minimizing the trimming scrap
    is one of the most modern and efficient is then simply a logical consequence.”
    hot-dip galvanizing lines worldwide. „The one who is able to The predictions here are based on data
    Since its commissioning in 2001 some define a problem has regarding strip width changes as a
    480,000 tons of hot-dip galvanized steel already half-finished it“ function of all equipment and material
    sheet have been produced annually. With parameters that are taken over a
    its modern equipment, high degree of  Julian Huxley longer production period. To this end,
    automation and wide product portfolio, ThyssenKrupp Steel Europe installed
    the plant sets new standards world­ one EMG strip width measurement
    wide. The products range from flexible It therefore creates a significant ­waste of system (BREIMO) in the intake and
    IF-steel to high-strength TRIP-steels. raw as well as operating materials such as one in the outlet of the annealing
    Nearly 100 percent of the manufactured acid, roller materials and zinc. The goal for furnace, just before the trimming
    products are designed for the automotive ThyssenKrupp Steel Europe is therefore to shears. The changes in the treatment
    industry. Exclusively galvanized material make processes more efficient, minimize process are thus visible. In conjunction
    is produced that has a high proportion width tolerances, save expensive with the EMG-SWOp (Strip Width
    of body shell quality – such as for car resources effectively, and above all to Optimization) software and database
    roofs or hoods. A large proportion of elimi­nate trimming scrap to the greatest environment, the overall system for
    material here is delivered directly from extent possible. strip width optimization is created.
    the line to the customer without further For this purpose, the measurement data
    processing steps. Thanks to the laser EMG’s solution for the two BREIMO systems are recorded,
    welding ­machine installed at the line’s „The one who is able to define a problem analyzed and visualized.
    intake, standard coils can be produced, has already half-finished it,“ Julian
    on which the laser weld process is fea­sible Huxley (founding father of UNESCO) BREIMO is an optical system for detecting
    without any trouble. once said. And in precisely this way the strip edges by the use of high frequency

    .moving ahead.
    EMG Automation GmbH  |  Industriestraße 1  |  D-57482 Wenden  |  Unternehmensgruppe
    Tel: +49-2762-612-0  |  Fax: +49-2762-612-237  |  info@emg-automation.com  |  www.emg-automation.com
    (HF) alternating light-measuring sensors it can predict malfunctions and offers of about 950 tons per year. Material
    that are insensitive to ambient light which, opportunities for timely intervention. that does not have to be paid for and
    by means of adjustable slides, are movable processed, or ends up as scrap. In this
    and steadily follow the respective strip respect an investment in BREIMO and
    edge. The traverse path of each adjustable In operation SWOp pays for itself in significantly
    slide is determined without contact and „All the expectations of the system have less than 6 months.
    the actual width of the running strip is been fully met,“ reports Dr. Peters, head
    calculated from the positional difference. of surface coating and annealing at In addition, all recorded measurement
    Each measuring sensor is equipped with ThyssenKrupp Steel Europe in Dortmund. results flow into the quality management
    a reference receiver which detects the „The scrap output for hot-dip coating line system (QMS). Each measured meter
    background brightness of the HF light 8 has been minimized, whereby we have of strip delivers 270 meters of measured
    source. Deviations in measurement due to been able to achieve tremendous savings. data. Aside from increasing the produc­
    contamination are thus compensated for. The operation of the line has increased tivity of the line, the consumption of
    Influences by external light sources are in its safety and the staff is greatly operating materials such as acid, roller
    eliminated through the use of HF-light relieved. More­over, the cooperation and materials and zinc were significantly re­
    transmitters and receivers. The measuring communication with EMG was and is duced – savings that also especially benefit
    accuracy of BREIMO in this case is ± 0.5 always constructive and successful.“ the environment.
    mm, but can be delivered at even higher
    specifications in a model with accuracies
    up to ± 0.3 mm. „All the expectations of Outlook
    the system have been fully Due to the similarity to the set of
    First, the average deviation of the supplied problems the system was designed not
    width from the ordered width and the
    met. The cooperation and only for hot-dip coating line 8, but also
    contraction in the particular production communication with for the continuous annealing line. In
    line for the most diverse materials are EMG was and is always the meantime it could also be put into
    determined with the system. From this construc­tive and successful.“ operation there. The transfer to other
    data the reserve is then determined for lines at ThyssenKrupp Steel Europe
    the customer ordered width, allowing for  Dr. Klaus Josef Peters is tested and gradually initiated by
    the strictly observed minimum trimming the Process Techno­logy department
    span. This minimal additional margin is that was created exclusively for
    extremely important for the function of The installation situation on hot-dip coating such purposes. A visible step in this
    the trimming shears. If it gets too small, line 8 presented no special challenges to the direction is the now completed third
    it can lead to damage to the cutting tools measurement systems. The connection of installation of the EMG-SWOp solution
    and thus to a complete line shutdown. the plant to the control system took place at hot-dip galvanizing line 7 (FBA 7) in
    via Profibus-DP (Profibus for Decentralized Bochum. The system has thus proven
    Through the combination of installing Peripherals). The installation went quite itself and paid for itself in a short time
    the BREIMO width measurement smoothly and ­without any negative impact at various facilities at ThyssenKrupp Steel
    system along with the SWOp data on production and output, since the Europe.
    processing and visualization, strip regularly scheduled plant shutdowns were
    widths smaller than the minimum used for this. The optimization of strip width with
    trimming span are now reliably EMG-BREIMO and EMG-SWOp is worth­
    detected. The equipment operator After a six-month period of while wherever strip material is trimmed
    receives an early warning signal data collection the processes at and a trimming span that is too narrow
    that allows him to direct the strip ThyssenKrupp Steel Europe with would result in plant problems. In addition,
    to a rewinder unit where still BREIMO and SWOp have meanwhile strip width inspection at the intake allows
    smaller trimming is possible. With the been optimized to the extent that for evaluation of the delivered strip width
    EMG system, risk management is thereby the ordered width could be reduced on the pre-aggregate side (e.g. hot rolling
    possible for the first time for deviations on average by around 3 mm. This mill, pickling line, tandem) and thus an
    in width at hot-dip coating line 8, as represents a considerable quantity optimization of the ordered width. 

    .moving ahead.
    EMG Automation GmbH  |  Industriestraße 1  |  D-57482 Wenden  |  Unternehmensgruppe
    Tel: +49-2762-612-0  |  Fax: +49-2762-612-237  |  info@emg-automation.com  |  www.emg-automation.com

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