Smart rolling mills

Rolling Mill

Unexpected shutdowns are costly and very demanding for the workforce involved. Make your rolling mill smart in order to increase the availability and quality output.

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 the rolling mill. 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 rolling mill, while it can be avoided, quite easily.

The only way to validate the actual health is by having a continuous look at a broad data set and adding a specific multi-aspect monitoring setup consisting of different sensor types that follow the behaviour of the rolling mills general state-of-health.

Our monitoring solutions can cover the different components of the line: shear, stands, looper, conveying rolls...

Check out our experiences
We understand the problems you face
Catch them before they cause greater damage!

Operational statistics
When continuously tracking currents or vibrations smart algorithms can determine automatically how long the belt operates under a certain condition. Live statistics give you insights into how optimally the asset is used.

Product quality
The more perfect the material, the higher its value. A perfect control of the stress distribution within the plate can be reached through permanent monitoring. The associated feedback loop allows generating a maximum amount of top-notch material, coil after coil.

Bearing degradation
A huge amount of axes means an equivalently high amount of bearings. When monitoring continuously those conditions that induce excessive damage can be detected and subsequently avoided to maximise bearing life.

Roll damage
A damaged roll means your entire production comes to a halt. Continuous monitoring of internal pressures allows preventing excessive local forces, thus roll damage.

Gearbox health overview
A very complex gearbox means complex problems. A permanent follow-up will help detecting misalignments or looseness in a nearly stage and will help preventing major problems as much as possible

Yield optimisation
The faster perfectly coiled rolls can be produced after starting a new coil, the less material has to be thrown away. A smart sensor set helps insetting the optimal set point to begin with and to rapidly reach the perfect conditions for each run.

MOTOR HEALTH | STRESS DISTRIBUTION | AVAILABILITY STATISTIC |
Compatibel with:
Our monitoring products are compatible with rolling lines or stands of the following suppliers:
Primetals
SMS
Sarralle
Danieli
Salico
Fives
Tenova
...
Software integrations:
All of Zensor's products are compatible with standard CMMS or EAM software. Connections can be set up to source the most recent interventions and changes on the asset, or to create a ticket when an intervention is required on a section of the rolling line. Compatible with:
IBM Maximo
IFS Ultimo
eMaint CMMS
Aveva
SAP
iba
...
Solutions
Learn more about our approach

Performance
Based on the data collected and machine-learning based methods for determining the operational condition the performance is calculated.
Quality
Coupling to existing databases or using human input fields the product quality is linked to operational process parameters.
Warnings
Whenever values start to deviate, or data streams stop, warnings are sent. This avoids 'black holes' in the insights of the production line or assets.
Increase availability
Have a continuous idea of availability, automatically as the platform combines different input streams and contextual information.
Our Experiences

Projects we work on:
Saarstahl
Neunkirchen, Germany

Zensor works with Saarstahl to optimise their wire rolling mill by understanding the damaging conditions affecting their components.

Projects we're working on:
Aurubis
Olen, Belgium

Zensor are proud to be working with Aurubis to help optimise their cooper wire rolling mill. Results to share soon...

Blog post:
Predictive maintenance is changing industry after industry
Predictive maintenance is no longer something that is reserved for big multinationals active in very specific industries....

Read more

Blog post:
Experience at Hüttentag
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.

Read on
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