Modern Automation Technologies Professional Magazine


Archives
 

НаименованиеInformation system for a slab cutter in a cogging facility

 

The technology of slabs production allows for the breakdown bar tail-piece trimming on the purpose of metal structural imperfections elimination. The following operation is performed on the special cutting-off machine. Normally 5% of the breakdown bar size are trimmed. As a result of a research made by engineers of the Scientific Production Institute “DONIKS” on the “Zaporozhstal” manufacturing facility the following data was obtained: the usable size of the trimmed part amounts to 50-200 mm. For this reason it was suggested to size up the trimmed part individually on a case-by-case basis depending on the ingot's type and the size of the breakdown bar, which will help to increase the yield. A demand for high-precision measurement of the trimmed part during the manufacturing process has arisen in the course of this project implementation and become the main task of the developed cutter information system.

A special measuring method was taken while system integration, when the cutting process image got from the video camera is digitized, a 3D reticle is superimposed on the breakdown bar tail-piece image and the whole process is visualized on a monitor.

The reticle scaling is performed basing on the breakdown bar size data, steel grade and type of ingot, which is transferred from the manufacturing process tracking system.

The cutting-off machine information system performs the following functions:

  • allows to gauge the trimmed part size within the 20 mm accuracy;
  • displays the recommended plan of the breakdown bar cutting;
  • marks the optimal size of the trimmed part on the reticle for easy measuring;
  • displays useful housekeeping information;
  • provides the EDI with top-level system;
  • detects and corrects errors while system operation.

The hardware component is Advantech industrial computer based with Pentium performance, which has an M-Systems flash memory working as disk storage. The software is С ++ realized.

The system implementation allowed to :

  • perform more exact breakdown bar cutting;
  • reduce the number of process errors while cutting;
  • improve the metal recordkeeping;
  • take measures for working environment improvement.

The annual 3000 tons metal-saving reflects high system performance while slabs production at the “Zaporozhstal” manufacturing facility.

Cutting-off machineVisual image of the breakdown bar tail-piece while trimming process (a 3D reticle is superimposed on the breakdown bar image, some fields of the image are marked, housekeeping information is placed in the bottom and on the top of the display)

Cutting-off machine

Visual image of the breakdown bar tail-piece while trimming process (a 3D reticle is superimposed on the breakdown bar image, some fields of the image are marked, housekeeping information is placed in the bottom and on the top of the display)

By Yevgeniy Azin, Sergey Budakva, Aleksandr Kuzmin and Ivan Fonotov

Yevgeniy Azin,  Sergey Budakva,  Aleksandr Kuzmin,  Ivan Fonotov