Automation Solutionsfor
Ladle Gate Applications
SEAISI 2009, Kuala Lumpur
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 2
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
Introduction
Key Aspects for Automation
Automation on Casting Platform
Automation of Ladle Gate Preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 3
Automation in today’s steel industry
Introduction
Increasing demand for automation solutions
Safety, process reliability and costs
INTERSTOP’s contribution
Automation solutions to complement INTERSTOP’s flow control systems
Focus on automation-ready process solutions
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 4
Safety
Key Aspects for Automation
Dangerous tasks
at ladle prep areaon casting platform
Coupling of casting cylinder
Handling of ladle shroud
O2-lancing
Break out of refractory
Handling of heavy loads
Automation
Solution to ensure safety
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 5
Key Aspects for Automation
Process reliability
Financial issues
Automation
Cost reduction
Cost savings
At ladle prep area
Reduced quality due to harsh working conditions
Operational safety issues
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 6
Manual coupling of casting cylinder
Automation on Casting Platform
Common practice:
With INTERSTOP’sSNAP coupling:
Mounting
Coupling
Release
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 7
Manual coupling of casting cylinder
Automation on Casting Platform Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 8
Automatic coupling of casting cylinder
Automation on Casting Platform
State-of-the-art
Base for automatic coupling is the SNAP coupling
Position detection and positioning purely mechanical
Worldwide first fully automatic ladle gate handling system
SSAB Tunnplat, Lulea, Sweden
INTERSTOP together with MTAG Marti-Technology
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 9
Automatic coupling of casting cylinder
Automation on Casting Platform
Near future applications
Robotic handling solutionse.g. LiquiRob® by Siemens VAI
Base for automatic coupling is SNAP coupling
Position detection and positioning by robot
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 10
Automatic coupling of ladle shroud
Automation on Casting Platform
State-of-the-art
Manually operated or semi-automatic manipulators
Manipulator remains connected during casting
Future application
Handling by automatic handling systeme.g. robotic solution
Ladle shroud clamping device as part of the ladle gate
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 11
Automatic coupling of ladle shroud
Automation on Casting Platform Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 12
Current situation
Automation of Ladle Gate Preparation
Harsh working conditions at ladle prep areas
Operators exposed to fumes, dust and high temperatures
Exhausting tasks for operators
Risk of
Reduced refractory lifetime
Breakouts
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 13
Vision - Automation System
Automation of Ladle Gate Preparation
All tasks to be automated
Modular concept
Automation-ready equipment
Specifically developed tools
Requirements
Robotic solution by automation partner
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 14
Sequence of ladle preparation
Automation of Ladle Gate Preparation Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
Start
PositiondetectionScenarioindependenttasks
Refractory check
Choose scenario
Scenariodependenttasks
Check & Release
Operator SystemResponsibility Tasks
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 15
Automation-ready ladle gate
Automation of Ladle Gate Preparation
Mounting cylinder with SNAP coupling
Easy tension release
Large access to refractory parts
Simple plate centring
CS ladle gate designed to adapt all features
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 16
Advantages
Automation of Ladle Gate Preparation
Cost savings due to higher process reliability
Cost reduction due to less operational efforts
Increased operational safety
Potentially dangerous tasks performed by the automation system
Improved quality management
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 17
Automation for ladle gate application
Summary and Outlook
Ladle gate specific task are due for automation in the near future
Driving features are safety, process reliability and financial aspects
Stopinc and RHI focus on solutions based on INTERSTOP’s automation-ready equipment
In short term robotic solutions on casting platform will be operational
In mid term INTERSTOP’s vision of the ladle prep area will become reality
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 18
INTERSTOP’s Vision Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook
SEAISI 2009: Automation Solutions for Ladle Gate Applications
May, 2009 19
End
Thank you
for your attention
Content
Introduction
Key aspects
Casting platform
Ladle gate preparation
Summary and Outlook