News
Newsletter
- Corus implements new optical roughness measurement system to optimize quality assurance
- Four leading international steel producers install new system for ensuring homogenous zinc layer thickness
- Contact-free edge mask control with EMG Edge Mask Control system
- EMG at METEC 2007
- Subsidiary of world market leader buys EMG-system for roughness measurement
- Newsletter: EMG-Newsletter_June_2007_L_E.pdf - [ PDF :: 1.2MB ]
Corus implements new optical roughness measurement system to optimize quality assurance
EMG Automation GmbH supplies Corus with its first EMG-SORM 3plus online measurement system
One of Europe's leading suppliers of steel, Corus, is using the EMG-SORM 3plus optical roughness measurement system to optimize quality assurance at its new hot dip galvanizing plant. The new system ensures higher quality by means of an optical laser scanning procedure that measures roughness while the strip is running.
The contract to supply the double-sided EMG-SORM 3plus system was signed in January 2007. It is being installed at the new hot dip galvanizing line at the Corus site in IJmuiden (the Netherlands) which is planned to go into production in 2008. It will produce steel strip for the automotive industry. The EMG-SORM 3plus system will ensure that Corus meets the automotive industry's high demands on roughness.
EMG-SORM 3plus is a non-contact online roughness measurement system. Unlike traditional methods where measurement is carried out offline on a sample taken from the strip, the SORM 3plus system measures roughness whilst the strip is running. SORM 3plus scans the surface topography to obtain detailed data on roughness. The data is saved, displayed online for the operator's information and may be transmitted to a higher-ranking network for further processing and analysis. Quality assurance is enhanced since the online scanning procedure delivers more detailed information than traditional, offline methods. SORM 3plus users know the roughness distribution over the whole coil and can base production and delivery decisions for the first time on that quality of information.
With the introduction of the EMG-SORM 3plus system, Corus invests further in process reliability, quality assurance and productivity. For EMG, it brings the total number of SORM measuring heads in use around the world to 29 and confirms that the system is on its way to becoming accepted as standard.
Four leading international steel producers install new system for ensuring homogenous zinc layer thickness
EMG supplies ThyssenKrupp Steel, Arcelor Mittal, Dongbu Steel and Baoshan Iron and Steel with eMASS system
Four of the world's leading steel producers, ThyssenKrupp Steel, Arcelor Mittal, Dongbu Steel and Baoshan Iron and Steel are using EMG's eMASS system (electro- Magnetic Strip Stabilization) to ensure a homogenous zinc layer thickness. The eMASS system ensures uniform thickness by reducing strip oscillation in the hot-dip galvanizing process.
Strip oscillations caused by fans in the cooling tower make it difficult to achieve a uniform layer of zinc. In order to meet customers' demands on minimum zinc thickness, it is normally necessary to apply an excessively thick layer. This increases production costs. By minimizing the strip oscillations, the eMASS system ensures a homogenous zinc layer at high production speeds, thereby maximizing the saving of zinc and the profitability of hot-dip galvanising lines.
The new systems will be installed at ThyssenKrupp, Mittal, Dongbu and Baoshan between May and October 2007. ThyssenKrupp has ordered two eMASS systems for its plants in Dortmund and Duisburg. At the Duisburg plant CGL #1, the system will be installed directly on the air knife where the zinc layer is controlled. This ensures optimal attenuation of strip oscillation and maximum zinc savings. "Depending on the experience and the target of the producer, the potential for zinc saving is significant", says Günter Schwanke of ThyssenKrupp Steel, who cooperated with EMG on the development of the eMASS system.
Depending upon requirements, the eMASS system can also be installed on the cooling zone. This is the case at ThyssenKrupp's Dortmund plant CGL #8 where the system will reduce strip twisting and movements caused by high performance cooling. In such an application eMASS allows higher throughput and more powerful cooling without the risk of strip damages.
eMASS was also the system of choice for Mittal at its coating plant in Columbus, USA. Lower maintenance costs and a damage-free strip were decisive factors in favour of the non-contact eMASS system over a cheaper, "touch rolls" solution. Dongbu in Korea will use the eMASS system in a similar way like ThyssenKrupp, Duisburg. With EMG's eMASS solution Baoshan Iron and Steel in China will acquire its first electromagnetic strip stabilisation system ensuring high quality and throughput for its 1550 CGL #2 line.
All four companies will also benefit from the system's new mechanical design with fast mechanical and electrical connectors for timely and easy installation on the air knife. Since the electronic sensors are integrated into the beam, control cabinets and power amplifiers can be placed 50m away. In addition, the air cooling system means no risk and low maintenance costs compared to water cooling systems. Fast assembly, easy changing of air knives and a turn-key solution that is tailor made to suit particular production lines round off the system's key features.
Contact-free edge mask control with EMG Edge Mask Control system
EMG Automation GmbH has developed a contact-free edge mask control system for continuous galvanizing lines
EMG Automation GmbH introduces its innovative, contact-free edge mask control system - EMG Edge Mask Control. The advantages: no mechanical contact with the strip edge above the galvanizing bath. The results: a homoge-nous strip edge and less damage to the strip.
"Our aim was to make the continuous galvanizing process even more reliable by ensuring the highest possible quality", explains Wolfram Münker, Head of the Development Team at EMG Automation GmbH.
Above the zinc bath and the air knives there are U-shaped inductive edge sensors on both the right and left edges of the strip. Under rela-tively high environmental and strip temperature, they continuously follow the deviation of strip edge positions without coming into contact with the strip. The edge sensors, which are based on the proven EMG magnetic induction technology, then control the follow-up of the edge masks by means of linear systems. Edge masks optimize the flow of air over the strip edges during galvanization and thereby pre-vent an undesired accumulation of zinc at the edges of the strip. The edge masks must be continuously adjusted according to deviations in the position of the strip and the various strip widths.
Normally, edge masks are followed-up using touch rolls that continuously follow the strip edge and are pressed against the edges by diffi-cult to control pneumatic cylinders. This is particularly problematic at high strip temperature, e.g. GALVALUME®, and low strip thickness and can lead to deformation of the strip edges and chipping of the zinc layer. This lowers the quality of the strip. The contact-free procedure from EMG replaces the touch rolls and therefore prevents chipping and damage to the strip. If necessary, the distance between the strip edges and edge masks can be adjusted in the production process.
EMG Edge Mask Control consists of the following proven EMG components: BMI 4 inductive edge sensors, an electro servo cylinder with electro-mechanical linear motors and control electronics based on SPC 16.
EMG at METEC 2007
EMG Automation GmbH will present state-of-the-art solutions at the METEC 2007, 12-16 June in Düsseldorf
For the seventh time, the International Metallurgical Technology Trade Fair will welcome industry professionals from around the world to Düsseldorf. As part of the METEC, EMG Servo-Technique Metal will present its latest solutions for optimizing efficiency, productivity, quality and competitiveness in hall 6, booth B/03.
EMG Automation GmbH specializes in the automation of continuous production processes in the metal, paper and plastics industries as well as in the foil and tire industries. The Servo-Technique Metals business unit develops strip guiding systems for the metals industry, especially for cold rolling mills and surface refinement lines. It also develops quality assurance systems for the non-contact measurement of material properties and for optimising the production process for the metals industry.
Innovations and trends around "QUALITY DURING CONTINUOUS STRIP PROCESSING" will be the focus of this year's trade fair. On display will be the IMPOC system for online measurement of mechanical properties, the SORM 3plus system for online roughness measurement and the eMASS system – electro-Magnetic Strip Stabilization. EMG will also present a paper on the eMASS system at the METEC InSteelCon 2007 conference which accompanies, and runs parallel to, the METEC 2007. EMG's Dr. Matthias Irle and Anno Jordan will explain how the innovative eMASS solution reduces strip oscillation, thereby enabling the production of hot-dip galvanized steel strips with homogenous surfaces, uniform zinc layer thicknesses and the maximum saving of zinc in the coating process. Using the eMASS system, it is possible to achieve all of these benefits at high production speeds. The paper will be presented to 600 registered international experts at the Congress Center Düsseldorf (CCD) on the morning of Wednesday, 13 June 2007.
We look forward to seeing you at the METEC in Düsseldorf from 12 - 16 June 2007 in hall 6, booth B/03!
Subsidiary of world market leader buys EMG-system for roughness measurement
ARCELOR MITTAL subsidiary, BREGAL of Bremen, Germany orders second system SORM 3plus from EMG
After successful probation of the first SORM 3plus system, purchased by BREGAL (Bremer Galvanisierungs GmbH) in October 2006, the company decided to order a second system for online roughness measurement from EMG Automation GmbH. Accurate roughness measurement of zinc layers is a considerable success factor for automotive steel suppliers.
Due to proven and tested collaboration, the system can quickly be implemented. With the second system BREGAL will also monitor roughness parameters on the reverse side of steel band during the manufacturing process. Thus the steel producer can immediately react to deviations during production. Installation and initiation are scheduled for September 2007.
EMG-SORM 3plus is an online measurement system for optical roughness detection of running steel strips. The device measures the surface roughness parameters of cold-rolled strips during production. Contrary to the traditional method for roughness measurement, the stylus instrument , the EMG-SORM 3plus works continuously and non-tactile. Roughness data are constantly observed and recorded over strip width and length. The system provides reliable measure-ment data on roughness at line speeds up to 2.400 m/min and is therefore ideal for fast production lines.
Roughness measurement is especially crucial for BREGAL because the manufacturer is the leading supplier for high-class galvanized steel products for the automotive industry. Due to the stringent quality demands of automotive companies, a strong zinc bond plays a decisive role in quality control during the metal forming process. BREGAL produces with a maximum thickness of 2.8 mm and width of 2.070 mm. The decisive requirements for the roughness of the zinc layers will be measured with the two SORM 3plus systems by EMG.
Contact
If you have any further question, please do not hesitate to contact:
Anno JordanSales Director Quality Assurance Systems
Phone: +49 2762 612 450
Fax: +49 2762 612 384
E-mail: sales@emg-automation.com
Internet: www.emg-automation.com
