Unexpected shutdowns are costly and very demanding for the workforce involved. Our Virtual Engineers help you to make your metal processing critical assets smart in order to increase the availability.
Today most often technical data sheets coupled with the knowledge of a number of unique experienced individuals are used to determine when maintenance is required for an asset. Product quality only becomes an issue when customers start complaining. Repairs are done when it's already far too late. All of this puts tremendous strain on the people responsible for the production and maintenance, while it can be avoided, quite easily.
The only way to validate the actual health of crucial assets, and predict upcoming issues, is by having a continuous look at a broad data set and adding a specific multi-aspect monitoring setup consisting of different sensor types. This combined with an automated smart follow-up of the behaviour of critical components and the general state-of-health of the asset based on the collected data.
Zensor offers a range of ready-made products for monitoring specific assets: Rolling bridges or Overhead Cranes, Electric Arc Furnaces (EAF), Hot Rolling Mills, Conveyors, AOD Converters, BOF, Continuous Caster turrets as well as Continuous Casting lines, Cold Rolling lines, including tensioners and welding stations, Cooling water pumps and de-scalers, ...
“The insights generated give us peace of mind regarding the overall status of the overhead crane. Prioritising, quantifying and investigating maintenance tasks became easier, which in the long run, will result in the avoidance of unexpected shutdowns."
"Predictive Maintenance is a buzzword. We on the other hand offer real solutions to solve real problems, including context and helping you to prevent them from happening ever again."
We understand the problems you face
Catch them before they cause greater damage!
Missing production targets due to equipment failure has a serious impact on your business and causes economic loss, delayed deliveries and demotivation among employees.
Not just the quality of the output but quality of the machinery - if your machine is deforming it will influence the quality of your output, causing greater bad yield.
The faster the asset produces perfect output one after another, the less material has to be thrown away. A smart sensor set helps in setting the optimal set point to begin with and to rapidly reach the perfect conditions for each day.
Increase the availability of your asset by only performing repairs when necessary.
Use the right data to discover where and how the problem came from.
When continuously tracking currents or vibrations smart algorithms can determine automatically how long the asset operates under a certain condition. Live statistics give you insights into how optimally the asset is used.
A typical steel plant process
Below a flow chart of a typical (integrated) steel plant or steel mill is depicted. It contains both process streams, bith the scrap-based as well as the ore-based route. In the future this flow chart will undergo massive changes, as for example DRI-based routed will replace the Blast Furnace process and Electric Arc Furnaces and also Induction ovens will take up the majority of the heavy lifting: the actual melting. Using the button below the chart a .pdf version of this chart can be downloaded.
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Last week Zensor attended the Hüttentag in Essen. During this annual event the entire German steel industry meets up to discuss the state of affairs and exchange ideas about upcoming developments and changes...