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Concept of Industry 4.0 for the Metals Industrie

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Presentation on theme: "Concept of Industry 4.0 for the Metals Industrie"— Presentation transcript:

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
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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
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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


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