Solutions for the Steel and Metallurgical Industry

Page 1:Solutions for the Steel and Metallurgical IndustryReliability and flexibility from a single sourceX12CrNi18-8

Page 2:Whether in the automotive industry, aerospace industry, energysupply, civil engineering or medical technology – steel and otherhigh-quality metals are indispensable for our world. Steel is the me-tallic material used most. This is because steel is extremely versatileand fulfills the highest demands.The consistent high quality of steel is ensured by state-of-the-artprocedures. This is the only way to attain continuous reproduction ofproperties such as corrosion protection, low weight or best ductility.The production of steel is highly complex and is carried out usinghigh temperature, shock and vibration under the most difficultconditions. This places high demands on producers and mechanicalengineers. They must guarantee a reliable process with best qualitymanagement. A fundamental prerequisite for this is the top qualityof systems and machines. This calls for the best technology.Balluff Solutions for theSteel and Metallurgical IndustryFor all types of steel production, Balluff provides first-class sensorsand systems with a suitable and up-to-date connectivity productline. Developed for rough environments, they are resistant to hightemperature, shock and vibration as well as extremely robust andreliable. Thanks to their excellent technology, they are also ideal forproducing other high-quality metals.Thus Balluff technology ensures greatest system availability and pro-vides consistent use of machine performance. In the coke plant, atthe blast furnace, in hot and cold rolling or during surface treatment.Balluff products are internationally approved and available worldwide.The global service offers individual support in the best quality, forBalluff is on site everywhere.

Page 3:Excellent Technology 4Coke Plant Machines, Coke Oven Battery and Conveying Equipment 6Blast Furnace and Electric Arc Furnace 8Continuous Casting Line 10Hot Rolling and Heavy Plate Production 12Cold Rolling and Surface Treatment 14Balluff Product OverviewsSpecial Connectors 16Fieldbus Modules for Global Use 17Industrial RFID Data Carriers for High Temperatures up to 220 °C18BVS Vision Sensors for Data Matrix and Bar Codes 19Standard Sensors for Object Detection 20High-temperature Resistant Inductive Sensors up to 160 °C 22Capacitive Sensors for High Pressures and Temperatures 23Ultrasonic Sensors 24Color and Contrast Sensors 25Rapid Replacement of Micropulse Transducers 26Micropulse Transducer with Explosion Protection 27Micropulse Transducers up to 100 °C 28P111 Module 28ProCompact Micropulse Transducer with IP 69K 29Redundant Micropulse Transducers 30Inclination Sensors 31Pressure Sensors 32Intelligent Power Supplies 33Accessories 34Safety Screen for Photoelectric Sensors 34HALT Test 35

Page 4:Hot rolling andheavy plate production lineBlast furnace4Full-range assortmentOur full-range assortment with all effective principles guaranteesthat steelworkers and plant engineers have excellent technologythat solves a wide variety of applications – whether for an electricarc furnace, a continuous casting line or a rolling mill.For the entire metal-producing industry and machine building indus-try, Balluff provides inductive, photoelectric, capacitive, magnetic,ultrasonic and pressure sensors as well as position measuringsystems and RFID systems – ideal for the extreme conditions in thesteel mill.Our networking and connectivity product line, ideally equipped forthe steel and metallurgical industry, is optimally designed for this; forexample, with PTFE cables up to 200 °C. All accessories for easymounting and installation or quick sensor replacement are likewisepart of our product line.Excellent TechnologyFor a wide variety of tasks in the entire processCold rolling andsurface treatmentContinuouscasting line

Page 5:Sinter plantCoke plantConverterElectric arc furnace5n www.balluff.comObject DetectionLinear Position Sensing and MeasurementCondition Monitoring and Fluid SensorsIndustrial IdentificationIndustrial Networking and ConnectivityAccessoriesSystems and ServiceHALT-testedBalluff quality for steel production means media-resistant as wellas resistant to high temperature, shock and vibration. Our productsare extremely robust and reliable, since they are rigorously testedin our own accredited laboratory using Highly Accelerated Life Tests.HALT tests help to optimize the resistance of our technology underextreme loads even before they are put into use: for high require-ments, optimum quality and best system availability.Individual solutionsBalluff gives you the best service and comprehensive services,including personal consulting and customized solutions. Contact us.

Page 6:6A continuous process is the foremost priority in the steel mill.Balluff provides steelworkers with extremely reliable solutions fora wide variety of tasks pertaining to coke plant machines, the cokeoven battery and conveying equipment.Where the process in the coke plant runs hottest is precisely wherethe robust position measuring system BTL 100 °C performs persua-sively. It reliably controls all movements related to furnace charging.Control of the oven itself is handled by a micropulse transducer withexplosion protection, which is ideally implemented in an environmentwith gas. At the coke oven battery, industrial RFID enables correctand fully autonomous positioning of the larry, pusher and transfercars. With a large read/write distance, super-fast data transmissionand no line-of-sight contact.Coke Plant Machines, Coke OvenBattery and Conveying EquipmentSteel production begins with coke

Page 7:For all movements at the coke oven batteryThe BTL Micropulse transducer in the hydraulic cylinder controlsall movements at the coke oven battery up to 100 °C. Its robustmetal housing with IP 67 and PTFE cable for up to 200 °C makesit ideal for particularly hot environments.Position detection at the pusher machineInductive sensors that are high-temperature resistant up to 160 °Cprovide the best results at the pusher machine for position sensingand detection of end positions.7n www.balluff.comControlling the pusher carsIndustrial RFID systems position larry, pusher and transfer cars atthe coke oven battery. Any number of write-enabled data carriersare embedded in the floor and read via a read/write device withouta direct line of sight. This technology provides data exchange in realtime. Even from a long distance.Controlling the coke oven batteryThe high-precision transducer with explosion protection isoptimally implemented if a gas environment requires high reliability –for example when regulating the oven control system.

Page 8:At no other place in the steel mill is process reliability as importantas at blast and electric arc furnaces. For once it is commissioned,a blast furnace is used around the clock over the course of years.For every steelworker, therefore, the importance of continuous andabsolutely reliable management of high temperature and of magneticfields is beyond dispute.Some of its important tasks are water cooling, safesupply and discharge of gas when producing pig ironin a blast furnace or positioning of electrodes in anelectric arc furnace.Blast Furnace andElectric Arc FurnaceContinuously manage magnetic fields and high temperaturesPositioning of electrodesSensors for detecting color and contrast support the positioningof electrodes in the electric arc furnace. The sensor, which is pro-tected in the gripper, uses color markings on the electrode to checkwhether it has been gripped correctly. The color markings are reliablyand flexibly detected even when their spectrum changes due totemperature differences.Assurance of the correct electrode positionWeld-immune BES inductive sensors operate extremely reliablywith insensitivity to magnetic fields at the electric arc furnace; thisprovides assurance of the correct electrode position.8

Page 9:Regulating the air and gas suppliesBTL Micropulse transducers are used for controlling flaps and valvesaround the blast furnace in order to regulate the supply and exhaustair during production of pig iron. Alternatively, standard BES induc-tive sensors deliver convincing performance.Additional security: A temperature sensor is integrated in the elec-tronics head for all BTL Micropulse transducers with a bus interface.This guarantees correct temperature measurement.Pressure measurement for the water coolingTheir exceptionally low drift makes BSP pressure sensors of particu-lar interest for pressure measurement of the water cooling at blastand electric arc furnaces, because they guarantee a long stable pro-cess. This makes Balluff pressure sensors unrivaled in the steel mill.Level monitoring of charges and cokeBUS ultrasonic sensors monitor stack heights of the bulk materialbeing conveyed on conveyor belts and the level in silos. In the caseof extreme dust and dirt from charges and coke, they provide forreliable charging of the blast furnaces.9n www.balluff.com

Page 10:Large forces, vibrations and shock have to be controlled in thecontinuous casting line: at the ingot mold movement for the homo-geneity of the fluid metal or at the walking-beam for transport ofslabs or billets.The steel quality is determined at the continuous casting segments.The desired properties are achieved depending on the degree,temperature and time of the reshaping. Therefore maximum flex-ibility and peak reliability are required for the technology used in thecontinuous casting line. Balluff sensors and systems provide securityand guarantee a consistent, continuous process for a wide varietyof product formats.Continuous Casting LineMaximum flexibility for various formats10Monitoring of the casting ladleBTL7 Micropulse transducers (2 and 3 times redundant) provideabsolute safety for the continuous casting process, since the ironladle movement requires maximum reliability.

Page 11:11n www.balluff.comChecking slab lengthPhotoelectric distance sensors are used at the cooling section.They check for the correct length after the slabs or billets havebeen cut.Position sensing at the dummy barBOS photoelectric sensors ensure reliable position sensing of thedummy bar. This reliably controls the beginning of the process.Fast replacement without leaksBalluff provides the rapid replacement module for fast andeasy replacement of BTL Micropulse transducers in the hydrauliccylinders. Replacement entails replacing the entire sensor unitwith the integrated waveguide elements. The hydraulic circuitremains closed.RapidReplacementModuleRRMTransport of slabs on the walking-beamBSI inclination sensors with contactless angle measurementguarantee ultimate precision when transporting the slabs onthe walking-beam. The mechanical coupling is unnecessary,as with rotary encoders.

Page 12:From the hot rolling to the heavy plate production, shock,vibration and large forces repeatedly develop. Water cooling is oftenrequired at the rolling stand. The equipment used here is subjectedto high moisture. For the great demands associated with reshaping,you receive first-class technology, which comprehensively managesa wide variety of work steps from the slab to the coil.Hot Rolling andHeavy Plate ProductionFor a continuously reliable process12BNI fieldbus modules up to 70 °C for all bus systemsBNI fieldbus modules are available for all important bus systemsto simplify the network topology. They enable the network to have amodular structure. In the steel mill, they delivery convincing perfor-mance to a high degree with their functional reliability up to 70 °C.IO-Link versions permiteffective and cost-effectivewiring of all sensors –standard sensors included.Guiding the slabsBTL Micropulse transducers in the hydraulic cylinder are ideal forpositioning and guiding the slabs. They check for the correctconfiguration of the lateral guides and accompany the slabs on theirpath through the rolling stand. The large forces in the reshaping arereliably compensated for in this process.

Page 13:13n www.balluff.comQuality assurance at the rolling standBIS M industrial RFID systems guarantee the automatic recordingand identification of all tools used. For example, they check whetherthe correct rolls are being used or whether the roll pairs match. Atthe same time, reworking of the rolls is documented. This consis-tently prevents errors and guarantees maintenance at the right time.An added benefit: RFID handhelds also enable mobile communica-tion right in the system.Correct assignmentBarcodes and color codes are used to clearly identify coils andother products. The BVS vision sensor quickly and reliably checksfor their correct assignment – independent of their position.Setting the roll gap preciselyThe roll gap can be set with high accuracy using the BTL Micropulsetransducer with IP 69K. The insensitive and vacuum-sealed BTLis perfect for use without additional protection for continuous watercooling of the rolling stand.

Page 14:Before the steel leaves the plant, it is processed for later use asmuch as possible. Rolled as a plate, wire or rail and provided withsurface refinement. Even the smallest errors here are irreversible,since the quality of the finish is visible later in the product. Thereforethe greatest measure of precision is sought.For cold rolling and surface treatment Balluff provides high precision:quality products for best performance even in the final stretch.For the dancer roll, winder, coating system or quality control.Cold Rolling andSurface TreatmentMaximum precision for the finishCorrect roll position at the winder and unwinderBTL Micropulse transducers are used to achieve high accuracywhen winding the coils. The pressure roller is guided, for example,depending on the roll diameter. Ultrasonics are used as well inthis process.14

Page 15:Reliable pressure measurement during surface refinementHCL-resistant BSP pressure sensors provide functional reliabilityduring the surface refinement process. They enable reliable pressuremeasurement of process media, even if they come into contact withaggressive medias like hydrochloric acid.Plate guidance at the dancer rollBUS ultrasonic sensors detect plates on rolls and coils and providefor the correct roller drive. In addition, they readjust the correct mate-rial feed at the dancer roll corresponding to the plate sag. Thus theplate tension is always perfect.Quality control at the coating systemThe BFS color sensor is ideally used for inspecting plate coatings.It detects the finest color nuances or whether a plate leaves produc-tion polished or unpolished. Even in the case of temperature fluctua-tions, it reliably identifies the plates. Thus the BFS provides unrivaledgood quality.15n www.balluff.com

Page 16:16A large selection of plug connectors and connecting cablesin different materials, colors and lengths can be found in ourcatalog Industrial Networking and Connectivity or online atwww.balluff.comOur comprehensive range of connectors includes connecting lines,assembled, customized and bus connectors as well as bus acces-sories. With variants specially designed for the harsh conditions insteel plants.We offer PUR, PVC, PTFE as well as TPE connections for the Ameri-can market to provide you with a range of versions that are resistantto aggressive media, high temperatures and weld spatter up to200 °C. We also offer torsion-protected, drag chain compatible,non-halogen and halogen variants.Special ConnectorsFor high temperatures, aggressive media and weld spatter

Page 17:17n www.balluff.comBalluff offers fieldbus and network solutions for the system level andIO-Link functionality for the sensor/actuator level regardless of thecontroller manufacturer.Balluff has developed fieldbus modules for the perfect connectionof IO-Link systems to industrial communications systems such asProfinet, Profibus or Ethernet/IP. These modules leave conventionalvariants far behind in terms of function and practicality. Enclosed in aFieldbus Modulesfor Global UseIn all network technologiessturdy, IP 67 metal housing suitable for steel plants, the new genera-tion is characterized by a wide range of configuration and diagnosticoptions visible via a display, LEDs and an integral web server.Ethernet-based modules also have an integral 2-port switch thatsimplifies the network design because without external switches,all modules can be connected directly with the controller in a linetopology. A complex star topology is no longer required.

Page 18:18The powerful, high-frequency BIS M data carrier is ideal for use insteel production because it has proven to be reliable in all appli-cations that require rapid data transmission over long read/writedistances in a harsh environment where high temperatures prevail.It records all data without making contact and makes it traceable.Unlimited read/write cycles ensure rapid, flexible communication,even when large quantities of data are processed. As a result, thewear-free system can be integrated in all types of controllers.The most important features■■ High-temperature resistant up to 220 °C■■ Extremely hard-wearing under mechanicaland thermal loads■■ Rugged housing■■ Global RFID standard ISO 15693, ISO 14443A■■ Typical read/write distance 45 cmIndustrial RFID Data Carriers forHigh Temperatures up to 220 °CRobust HF data carriers with 13.56 MHzRFID handhelds – Flexible mobile communicationRFID handheld readers in LF, HF and UHF technology are convenientto handle and guarantee flexible mobile communication becausethey do not have a cable guide. Software individually adapted to theapplication offers outstanding additional features: individual menusthat are intuitive to operate, information displayed in plain text andprotection from unauthorized access. Our RFID handhelds can iden-tify RFID and 1D/2D codes and can therefore overcome changes inmedia format.Data carrier for high temperatures (–40... 220 °C)112 bytesNXP ICODE SLIISO15693BIS00YE Ø 25×5 mmBIS00Y4 51.5×51.5×6.5 mmBIS00Y1 128×52×11 mm736 bytesNXP MifareISO14443ABIS00YA Ø 25×5 mmBIS00Y7 Ø 50×5 mm1 KbytesInfineonISO15693BIS00Y2 51.5×51.5×6.5 mm

Page 19:19n www.balluff.comMore information can be found inour Industrial Identification catalogsor online atwww.balluff.comThe BVS-E Ident reads all the most common bar codes and datamatrix codes quickly, safely and reliably up to 40 times per second.Irregularities in position such as those experienced during coil trans-portation are irrelevant because the sensor compensates for them.It also checks that the content of the code is correct and evalu-ates the code quality according to ISO standards, which increasesprocess reliability because codes that are difficult to read are reliablyejected. Slabs and coils can therefore be identified continuously.■■ Simple and intuitive operation■■ Read and verify bar codes and data matrix codes at the same time■■ Evaluate the code quality according to ISO standards■■ Code is read regardless of the position, even under difficult conditions■■ Verify character strings■■ Output of code data via RS232 or Ethernet interface■■ CE certified lighting – "eye-safe", even in infrared■■ External monitor available for better process tracking■■ Extensive range of accessories that meet industrial standardsReadable bar codes■■ Interleaved 2-of-5■■ Code 39■■ Code 128■■ Pharmacode, Codabar■■ EAN 8, EAN 13■■ UPC-A, UPC-E■■ PDF 417Readable data matrix codes■■ At high and low contrast■■ For shiny and reflectivesurfaces■■ For directly markedand mirrored codesBVS Vision Sensors forData Matrix and Bar CodesRead, check and evaluateSeries BVS-E Identification BVS-E Identification BVS-E IdentificationLens, focal length Standard lens, 8 mm Telephoto lens, 12 mm Telephoto lens, 16 mmPNP,red lightOrdering code BVS0001 BVS000T BVS000YPart number BVS ID-3-001-E BVS ID-3-003-E BVS ID-3-007-EPNP,infraredOrdering code BVS0019 BVS001A BVS001EPart number BVS ID-3-101-E BVS ID-3-103-E BVS ID-3-107-ESupply voltage UB 24 V DC ±10 % 24 V DC ±10 % 24 V DC ±10 %Switching inputs 1× Trigger, 1× Select 1× Trigger, 1× Select 1× Trigger, 1× SelectSwitching outputs 1× lighting synchron., 1× PNP 1× lighting synchron., 1× PNP 1× lighting synchron., 1× PNPInterface RS232 RS232 RS232Configuration interface Ethernet 10/100 Base T Ethernet 10/100 Base T Ethernet 10/100 Base TTyp. detection rate 3...40 Hz (depending onevaluation function)3...40 Hz (depending onevaluation function)3...40 Hz (depending onevaluation function)Working range 50...1000 mm 50...1000 mm 150...1000 mmWorking distance, 50 mm, 1000 mm, 50 mm, 1000 mm, 150 mm, 1000 mm,Field of view (horizontal × vertical) 25×18 mm 500×360 mm 16×12 mm 312×237 mm 34×26 mm 229×172 mmLighting LED, incident light, deselectable LED, incident light, deselectable LED, incident light, deselectableEye safety per IEC 62471 Exempt group Exempt group Exempt groupConnection 2× M12 connectors(8 and 4 pin)2× M12 connectors(8 and 4 pin)2× M12 connectors(8 and 4 pin)Degree of protection per IEC 60529 IP 54 IP 54 IP 54

Page 20:20Photoelectric sensors check presence, size, color, distance andthickness. They are excellent specialists with different focuses:■■ Part recognition and counting■■ Stack height monitoring■■ Detection through glass■■ Small parts alignment■■ Brand recognition■■ Fill level detectionand much moreInductive sensors are used to control, position and check processesin automation technology. The robust sensors detect objects in themetal range.■■ Non-contact, wear-free, contamination-resistant,short-circuit protected■■ Available in designs from Ø 3 mm to 80×80 mm squaredimensionsPhotoelectric sensors Inductive sensorsStandard Sensorsfor Object DetectionPowerful sensors in outstanding qualityDifferent working principles for object detection are available forthe wide range of tasks in the iron and steel industry: reliable levelmonitoring, the detection of markings, sensing in hydraulic cylindersor robust applications in the metal industry. Select the best solution.HOTZONEUltra-high temperature-resistant BNS single and multipleposition switches – for extreme applications up to 180 °CUltra-high temperature-resistant single and multiple position switchesare suitable for temperatures up to 180 °C. Enclosed in a robust diecasting housing, they require minimal space and are ideal for harshenvironments in the steel production industry, for example.