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DT Labs in metal industry

Robotic applications specially designed to improve process operations, making them safer and faster, in each production area: furnace, casting, rolling mills and process lines.

The most advanced alliance between industrial robotics – specifically manufactured for use in harsh environments - and process automation fully compliant with Industry 4.0 systems and architectures.

SAMPLING & MEASUREMENT

SAMPLE: EAF/LF steel bath temperature measurement and physical samples taking for lab analysis with automatic cartridge loading/unloading. Constant depth and tilt of the lance, compliant with the EAF range of positions, is set and monitored from the HMI; tap to tap time is reduced since EAF can remain in power-on mode during the sampling

The robotic cell is provided with water cooled sampling lance, metal shields and fiberglass thermal dress; the anti-collision function allows the automatic repositioning of the lance in case of solid scraps or obstacles on the trajectory of the robot.

EBT LANCING

Q-MELT EBT: automatic EBT cleaning, opening and unclogging.

Automatic nozzle position acquisition by means of a 3d vision system; remotely operated control of the robot by jog functions through the Joybot portable console.

FURNACE SCAN

Q-MELT SCAN: automatic visual inspection of the internal of the EAF through a 360° video camera mounted on a dedicated tool compliant with the sampling lance (no tool-change required).

All images can be visualized on a PC monitor /tablet/smartphone using the dedicated application integrated in the HMI. 

LADLE

  • Sample & measurement
  • Lancing
  • Shroud manipulation
  • Tundish powder
  • Cylinder preparation

Q-CAST LADLE: "zero operators" multifunction two-robots cell to allow fully automatic operations in ladle area of casting floor

Shroud manipulation:

  • nozzle position acquisition by means of a 3d vision system fully integrated in the handling tool
  • shroud picking from the rack and insertion on the (idle) slave manipulator, dragging of the manipulator to couple the shroud with the nozzle.
  • slave manipulator back to parking position and shroud to oxy cleaning station or rack (when it has to be replaced) after the casting

Lancing:

  • nozzle emergency oxygen lancing in case of non-spontaneous opening
  • nozzle position acquired from robot #1 video system
  • electrical or gas lighting

Sampling & measurement

  • tundish steel bath temperature and chemical composition measurements: oxygen (CELOX), hydrogen (HYDRIS), physical samples for lab analysis (IDCAS) with automatic cartridge loading/unloading.
  • dedicated lances with automatic tool-change and relevant tools for each function stored in a specific rack.

Powder addition

  • tundish powder automatic dosing and distributing to guarantee a thin and uniform powder thickness over the whole casting process
  • optional cast-eye sensor-camera to check the powder thickness and bath coverage.

Q-CAST LADLE CYLINDER: ladle sliding gate hydraulic cylinder manipulation and mounting.
Fully automatic or remotely operated operation through the Joybot portable console with no human intervention underneath the ladle.

MOULD

  • Powder feeding

Q-CAST LADLE MOULD: automatic casting powder dosage and feeding in continuous casting machines with up to four different hoppers.
Optional cast-eye sensor-camera to check the powder thickness and bath coverage.

FINISHING

  • Tag
  • Mark
  • Punch
  • Deburr

Q-CAST TAG: automatic tagging system with fully customizable metal labels resistant up to 850°C welded (with/without pins) on billets, blooms, beam blanks on the cooling plate; complete products traceability

Green project ®  - qualified Danieli partner - marking & reading systems technology.

TAG MARK

TAG

BUNDLE: automatic label welding system for bundled rods; a 3d vision system is used to identify the "best" bar for label application.

COIL: label clip holding system fixed on the coil strap; a 3d vision system identifies the "best" point for label placing

Complete products traceability.

MARK

Q-ROLL MARK: automatic paint spray marking system in multi (dot matrix) or mono (handwritten-like characters) version for flat products; complete products traceability

Green project ® - qualified Danieli partner - marking & reading systems technology.

DESTRAP

Q-ROLL DESTRAP: automatic system for strap removal from steel coils, profiles or tube bundles; a 3d video system is used to identify number and position of straps that are cut with a dedicate pneumatic scissor and winded, compacted and ejected as scraps.

DEBURR

Q-ROLL DEBURR: stand-alone robotic cell proposed with different custom designs ranging from billets chamfering to heavy blooms deburring and from saw-generated burr to heavy cutting torch effect.

A 3d vision system allows the robot to identify and follow edges even in unknown position.

SAMPLE PREPARATION

Q-ROLL SAMPLE PREPARATION: stand-alone fully automatic cell with 2-cooperating robots cell for master samples cutting, deburring and marking downstream the rolling mill area.

Positioning and shape of the masters are automatically detected to perform the sample withdrawal and deliver with no auxiliary pusher system or manipulator.
The solution can be customized and adapts to existing layouts without any mechanical modification.

SKIM

Q-ZINC SKIM: automatic skimming and dross removal system for zinc baths.

A continuous cyclic passing across the surface of the zinc driven by a control system that adapts the skimming speed to the dross production amount in compliance with the bath level.

INGOT

Q-ZINC INGOT: automatic feeding of the zinc pot with zinc and aluminum ingots or jumbo premixed ingots.

Automatic control of zinc pot receipe and Zn-Al consumption, level control, reduction of waves during ingot loading, overall reduction of dross production.

DESTRAP

Q-ZINC DESTRAP: automatic system for strap removal from ingots palletts; a 3d video system is used to identify number and position of straps that are cut with a dedicate pneumatic scissor and winded, compacted and ejected as scraps.