automation of data collection and data analysis1.ppt€¦ · automation of teeming data collection...
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Automation of Teeming DataCollection and Analysis at EQS
Prepared forIngot Metallurgy Forum
Spring Meeting 2009Brendan Connolly
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Online Teeming Bay
• Teeming is a critical step in production of high-quality forging steel
• Steelpourer must work safely and efficiently inorder to ensure the best possible pour
• Hand-written reports have been used in theteeming bay since EQS began production
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Online Teeming Bay
• Automating the data collection in the teemingbay allows us to take advantage of the databeing in electronic form:
– Real-time information
• End teeming time
• Strip time
• Pour rates
– Reduced possibility of errors
• Times are automatically pulled into reports
• Pour rates are direct readings from scale
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Online Teeming Bay• But, a system such as this does not just convert to
electronic data for the sake of technology
– MORE data is now collected
– Easier access to data
– More information is available to the steelpourer
• The data should be collected with the least operatorinput necessary
– Hand-written records required pour rates every 5 minutesto be recorded
– New system is recording the rate every 30 seconds, andthe operator can concentrate on other important issueswith the heat
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Online Teeming Bay
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Online Teeming Bay
• System automatically pulls the necessary data(pour rate, flux amount, hot top setting, etc.)from Level 3 computer system
– Automatically displayed on handheld tosteelpourer
– Date tables can be changed easily by QC
– Can be manually overridden by steelpourer ifnecessary
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Online Teeming Bay
• IT System set-up time = 9 months
– Massive amount of programming to ensure thatsystem was fully integrated with current Level 3computers
– Research, trial and error for determining besthardware for this application
• Implementation time = 6 months
– Training of all steelpourers under parallel systems
– Verifying all data is accurate
– Correcting any “bugs”
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Level 3 System
•Mold Data•Grade Data•Job Data
Level 2 System
•Grade Data•Heat Data
Handheld TeemingSystem
•Operator Data Entry•User Interface
TeemingScale
Teeming Record
•PDF electronically filed
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Online Teeming Bay
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Online Teeming Bay
• Teeming records have a tendency to ignitewhen hit with sparks!
– Electronic versions are saved in the system andcan be accessed and re-printed by anyone
• When there are other events that drawattention from record keeping, the manualteeming records can have data missing
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Online Teeming Bay
• Teeming rate data is automatically comparedto aim teeming rates for each steelpourer
• Steelpourers are given their results eachmonth to review
• Most steelpourers have since been able toachieve 90%+ teeming within +/- 5% of aimrate
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Online Teeming Bay
• Stripping ingots early can cause them to bescrap
• The online teeming system has beenprogrammed with visual interfaces to show:
– Where each heat is located
– When it is ready to strip
• Touch-screen technology aids in preventingmis-typed heat numbers when printing tags
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Online Teeming Bay
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Online Teeming Bay
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Online Teeming Bay
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Online Teeming Bay
• Prevention of early / late strips
• Real time updates of setup locations and striptimes
• Easy user interface for tag printing
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Online Teeming Bay
• The real-time data collection is expected toallow us to expand the automation in shipping
– Better control of ingot thermal handling
– Prevention of stress cracks
– More efficient furnace utilization
– Easier data access
• End teem times and strip times that areaccurate and electronically available arenecessary to properly analyze ingot coolingcycles