1. Concept of Industry 4.0 for the Metals Industrie
Třinec, 30. Nov. 2016
Restricted © Primetals Technologies 2015 All rights reserved.
primetals.com

2. Customer requirements Achieved by Holistic Automation
Digitalization is driven by new customer requirements and enabled by new technologies
Customer requirements
New Technologies
End-customer integration
Communication Technologies
Lot-size 1
Computational power
New business models
Internet technologies
Know-How management
Cloud technologies
Supplier integration
Big data analytics
New steel grades
Self-learning systems
Availability of information
Mobile devices
Ergonomy / Operator support
Augmented reality
Achieved by Holistic Automation
K.Herzog / EA I4.0

3. A digitalized plant is like an orchestra – The Metals Orchestra
K.Herzog / EA I4.0

4. Metals Orchestra Teach your players to play better
K.Herzog / EA I4.0

5. Smart Sensors help to improve data availability
Measurement Identification Communication Tracking
Scrap Chute Tracking
Ladle Tracking with RFID
Pallet car tracking with RFID
ICE-Tag Protection
Tracking of equipment allows equipment-related data collecting. So for example the complete history of a ladle can be collected and this history can be used for predictive mantenance.
Our RFID-based ICE-tag can withstand high temperatures ( up to 600° for 15 minutes) in can therefor be used in harsh environment.
Temperatures
Ladle history
Identification
Tracking
Scrap Weight
Wireless transmition
Improved Tracking and Input Data for the Process Models & Data Analytics
K.Herzog / EA I4.0

6. Robotics LiquiRob
Temperature measurement Shroud handling Oxygen lancing
Lock out of personnel from hazardous working areas
Minimal maintenance required
Customizable robot tasks to guarantee high flexibility
Ensures reliable production
Quality improvement due to reproducible procedures
Highly scalable (i.e. basic systems to highly sophisticated implementations)
Page 6
EA ISC

7. Steel Expert Process Models A digital twin of the real plant
Hot metal and scrap order
Steel Expert Prediction
Precalculation of complete heat
Preview of blowing process
Adaption of treatment practice
Modelling
Steel Expert Setpoint
FCC First Charge Calculation
SCC Second Charge Calculation
Inblow (Sublance model),
Reblow ; Alloy
Simulation
Optimization
Steel Expert Supervision
Online tracking of steel and slag analysis, temperature and weight
Model-based
Control
Dynacon
Dynamic blow end control based on off-gas data
Prediction: Offline model for simulation of the entire blowing process based on input material data and selected blowing patterns
Setpoint: Based on the target analysis and quantity, optimized hot metal and scrap mix is calculated to order hm and scrap. Based on delivered hm analysis and scrap analysis and weight, the hm charging weight is precalculated. Models for inblow, reblow and alloying calculate setpoints for the entire blowing and tapping process.
Supervision: cyclic recalculation of temperature and steel bath analysis; corrected by actual measurement
Dynacon is a dynamic blow-end calculation based on off-gas analysis measured by the LOMAS system
Tapping
Advanced Tracking System (Ladles, Scrap chutes, Slag pot)
Wiplant (HM weight, Scrap weight, Slag weight on transfer cars)
LOMAS – Low maintenance offgas analysis system
Ignition guard
Slagmon ( Slag warning system for tapping)
Automatic tapping
supported by Smart sensors and Automatic Functions:
K.Herzog / EA I4.0

8. BOX CONCEPT One Source One centralised Condition Monitoring System
Iron and Steel- making
Caster
Rolling
mill
Process-ing Lines
Utilities
supply
BOX Concept Informationbroker
Condition Monitoring
System
Maintenance/
Process Team
Mechatronics
Technological controls (Level 1)
Process models (Level 2)
Process
Vibration monitoring
Automation
Single source
with plant wide
data collection
3rd-Party Information
M2M
Interface
Plant-
Equipment
K.Herzog / EA I4.0

9. Smart Work Augmented reality supports maintenance personnel
Seamless linking of data from the HMI, condition monitoring, diagnostics, automation system
Reliable identification of plant components with RFID tags or QR codes
Checking the precise installation location of sensors and actuators in 3D displays
Checking sequences in animated displays
Retrieving live and diagnostics data from the automation system
Retrieving online documentation
Smart work: smart work is about interlinking all data to provide exactly the information, maintenance people or operators need to do their job.
Efficient troubleshooting and fast, direct access to the required information
Shortens search times, and reduces errors and mistaken identities
K.Herzog / EA I4.0

10. Acoustic Expert Data Based Services
Cloud Service
UMTS
Internet
Benefits
Automatic detection of equipment malfunction
Maintenance support
Island system – no access to plant network from outside possible
Secure / encrypted data transmission
Comparison of different plants possible
To make the information available everywhere and to have little impact on the existing automation system, this acoustic expert is a cloud-based service.
Pre-evaluated sound information is sent to a cloud server, where the final evaluation is done and the reports are created. The reports can be vizualized via an app on any mobile device.
For sure, data transmission is based on highest security standards.
Plant
Automation
K.Herzog / EA I4.0

11. The Digital Unity – The Conductor of the Metals Orchestra
K.Herzog / EA I4.0

12. The Digital Unity – The Conductor of the Metals Orchestra
K.Herzog / EA I4.0

13. The Digital Unity – The Conductor of the Metals Orchestra
PMS dynamically plans and tracks your production to utilize your production facilities in an optimized way, from the customer order down to each individual production step.
It optimizes productivity and ensures maximum flexibility to your customer requests.
TPOpt provides know-how based identification of non-conformities, identifies the related root-cause and provides corrective and compensational actions through- out the entire production chain.
It effectively helps to achieve the intended product specifi- cations and supports your quality management.
Maintenance Management assists you manage and execute your maintenance in an entirely new way. Built in know how generates actionable items, according to your strategy, increases efficiency of your maint- enance personnel and unleashes the true value of you assets.
K.Herzog / EA I4.0

14. Quality along the entire production chain Through-Process Optimization (TPOpt)
Challenge
Complete genealogy from heats to finished products.
Product quality conformance checks for the entire production chain
Many different data sources
Product Genealogy across the entire production chain
Solution
Quality monitoring functionality
Know How documentation
Defect Classification & Corrective Actions (feed forward & feedback)
Big Data storage for analysis
TPOpt is an important element for the horizontal integration in the Smart Factory
PRIMETALS TPOpt = Quality Management +Root-Cause Identification +Corrective Action
Data analysis is combined with an rule-based expert system
Benefits
Quality management support
Reduced manual inspection, rework and downgrades
Support for quality certification (ISO/TS16949)
Reduced influence of human-factor
No of references: 150 slab caster
ROI: ??
K.Herzog / EA I4.0

15. Summary and Conclusion
Industrie 4.0 Strategy
Industry 4.0 will not be available “off the shelf”
Digitalization started years ago and will not be finished within a few years
Each steel plant must define their own particular implementation strategy
Primetals Technologies will actively assist plant operators in the digital transformation of their production plants with portfolio elements and services
Primetals Technologies supports
Developments in all directions: Quality, Productivity, Flexibility
Industry 4.0 Readiness
Immediate customer value
Implementation step-by-step, e.g. in Modernization Projects
K.Herzog / EA I4.0

16.
K.Herzog / EA I4.0

17. Kurt Herzog Head of Industrie 4.0 Primetals Technologies Austria GmbH
Contact
Kurt Herzog Head of Industrie 4.0
Primetals Technologies Austria GmbH
Turmstrasse 44
4031 Linz
Austria
T +43 (732) M +43 (664)
primetals.com
K.Herzog / EA I4.0