Bestact for Harbor Facilities, Iron Steel and Cement Making Plants

Transcription

1 MANAGEMENT SYSTEM MANAGEMENT SYSTEM Bestact for Harbor Facilities, Iron Steel and Cement Making Plants CERTI F I ED CERTI F I ED QUALITY SYSTEM ISO9001 JQA-0792 ENVIRONMENTAL SYSTEM ISO14001 JQA-EM0202

2 Bestact allows for safe operation of Harbor fac Harbors of steel and electrical facilities are exposed to dust, dirt, corrosive gas while handling large quantities of industrial material such as iron ore and coal. Due to their large scale and high degree of automation, reliability, safety and durability and uptime are a must for any electrical component being used in these applications. From unloading raw materials at harbors to fabricating steel derived products, productivity is the key for these processes which are becoming more automated and operated automatically by computer systems. In contrast, various sensors used in these environments are often damaged. Malfunction of these sensors halt production lines and lower overall productivity. By virtue of its high reliability, Bestact serves as the best solution for sensor application in the fields of steel and cement making plants. Bestact products take active roles in large scale harbor facilities, iron, steel and cement plants. Examples of the processes that Bestact products are used in are shown below. Please refer to the appropriate page number for more detail. Iron and steel manufacturing flow Iron making process (Coal) (Iron ore) 1 3 Harbor facilities (Loader/Unloder) P.4 2 Harbor facilities (Belt conveyor) P.5 Raw material yard (Sintered ore) P.6 Sintering Sinter iron ore and produce sintered ore. 4 Tramcar P.6 (Coke transportation) Coke Bake coal in an oven and produce coke. 5 Iron making plant P.7 2

3 ilities due to its reliability. Steel making process (Molten steel) (Scrap iron) Basic oxygen furnace Pig iron converted to molten steel (Molten iron) (Molten iron) Continuous casting Cooling down molten steel and cast slabs continuously. (Slab) (Coke) Blast furnace Raw materials are put into the top of blast furnace and pig iron (molten iron) comes out from the bottom. Torpedo car Transporting of molten steel by torpedo car Rolling process 6 Hot strip mill P.8 Slab is rolled with a rolling machine. 7 Cold strip mill P.9 Slab is milled with a rolling machine. (Hot-rolled coil products) Continuous hot-dip galvanization 8 P.9 (Cold-rolled steel) 3

4 Usage by application 1 Harbor facilities (Loader/Unloader) Unloader Application to detect position of a crab trolley (traversing direction). Ship loader Application to detect rotating position Harbor facilities incorporate raw material handling machinery such as unloaders and various cranes, reclaimers and stackers for transferring, stacking and discharging iron ore and coal, and belt conveyors arranged in between these machines. Due to their close proximity to coastal areas and their handling of large quantities of industrial materials such as iron ore and coal, the harbor facilities are exposed to an environment where dust, corrosive gas, rain water (muddy water) are commonplace. A Bestact limit switch, PIKU-110R25A-01 is installed on a girder of an unloader in order to prevent an accident that may be caused by an overrun of the crab trolley slipping on the rails. PIKU-110R25A-01 is a vane type limit switch; it is non-contact sensor that avoids the pitfalls associated mechanical contact limit switches and sensors. It has high switching reliability and durability under severe environments. << Product Model >> Anticorrosion limit switch PIKU-110R25A-01 4

5 2 Harbor facilities (Belt conveyor) The Bestact PSKU-110R25CB is used for the reversing of conveyer belt operation and detecting belt derailment, where the dust condition is especially severe even among harbor facilities. Device used to reverse direction of a conveyer belt Unloader with a retractable crane Mantrolley type unloader Rope trolley type unloader Device used to detect belt derailment Portal bridge crane with a retractable crane Tower type jib crane Self-propelled low-floor jib crane Stacker Belt conveyor Harbor facility << Product Model >> Heavy-duty limit switch PSKU-110R25CB Iron and steel making plant Power plant Various harbor facilities 5

6 Usage by application 3 Raw material yard Dust generated from conveying coke and raw materials adheres to conventional switch devices and impairs their ability to operate reliably. Consequently, industrial engineers crave switches with longer life and without contact problems. Bestact built in limit and proximity switches can meet such demand due to the sealed contact that is used. 4 Tramcar (Coke transportation) During raw material transportation, low-level signals are needed for detecting trolley position For detecting position of trolley and for opening/closing status of a hopper gate. For detecting position of a trolley of stacker in an iron and steel making plant Hopper Cylinder Control box Magnetic proximity switches For detecting position of a trolley in cement curing furnace << Contact Unit >> 6 << Product Model >> Magnetic proximity switches PSMS-R3D1H PSMM-R3D1H

7 5 Iron making plant Bestact output contacts are used in the master controller in iron making plants. Slide movements of a cam operate conventional contacts. However, the cam often seizes and oxide coating forms on the surface of contacts due to the severe operational environments and thus causes switching problems of conventional contacts. A Bestact vane type magnetic proximity switch improves reliability of output contacts and mechanical durability of a main operational switch in iron making plants. << Product Model >> Selector switch PLRC-G << Contact Unit >> 7

8 Usage by application 6 Hot strip mill Hot strip mill is one of the most common facilities in steel fabrication. Each slab is reheated to over 1000 C in a reheating furnace. It is then run into a hot strip mill set up as a continuous strip at speeds of more than 80 km/h where it is flat-rolled. In a highly automated facility, slabs are run into this mill on the order of every 30 to 45 seconds. The steel manufacturing industry is on a par with the textile industry in terms of its large consumption of water. Generally speaking, in the fabrication of steel, the blast furnace and hot strip mill will consume the most amount of water. Also in this process a large amount of rolling oil is mixed with the cooling water and is used to prevent abrasion of the work rolls. In addition to this, various lubricants are applied to the mill stand itself (such as grease for bearings, hydraulic fluid, etc.). Consequently, electrical devices will be exposed to severe heat, humidity, water and oil splash and if one of the electrical components should fail in this application it would be a very costly in terms of lost production. 8

9 7 Cold strip mill Hot coil Acid cleaning pickling process Cold strip mill * 2 An image of cold strip mill * 1 Usage environment The frictional heat developed between the work rolls of cold strip mill and metal sheet increases the ambient temperature to near 100 C. In addition to this, lubricant is applied to the sheet metal during this process and creates an environment with high temperature and humidity. Advantages of Bestact columnar type magnetic proximity switch Bestact columnar type magnetic proximity switches are used as sensors for detecting positions of work rolls* 1 and winding length of the coil* 2 in cold strip mill applications. They exhibit very high reliability and electrical life. << Product Model >> PSMS-RV4G1THL PSMS-MV10TH << Product Model >> PSMS-RV3G1TSL PSMS-MV10THA 8 Continuous hot-dip pickling galvanization For continuous hot-dip galvanization, Bestact magnetic proximity switches detect position of a supporting board that is used for feeding coils into the process. Lead-in wire Conventional detector SW Rotation Home position detector SW The position during the coil is rolled. PSMS-RV1G1TH Home position Detector SW to detect the position during the coil is rolled Actuator PSMS-MV10THA PSMS-RV1G1TH PSMS-RV1G1TH 2 switches Coil feeding in hot-dip galvanization process Usage environment For the galvanization process, Bestact proximity switches are exceptionally suited for harsh conditions such as vapor acid cleaning and oxidization processes. PSMS-MV10THA 9

10 Usage by application Auxiliary contact applications The advantages of conventional auxiliary contacts are electrically and mechanically durable, structurally simple and can be easily maintained. However, after the advent of PLCs, low level signaling (24 VDC, 10 ma) of contactor status became predominant and the use of conventional auxiliary contacts led to contact failure for such signals. Bestact auxiliary contacts are ideally suited for this type of application Auxiliary contacts for a circuit breaker due to their wiping action and immunity to the surrounding environment. They have improved reliability significantly. Shown below are examples of applications where Bestact auxiliary contacts are used. Bestact contacts are utilized for auxiliary contacts for circuit breakers and control panels of power distribution devices. Auxiliary contacts for a control panel of power distribution device 10

11 High Reliability, Inherent in Stringent Quality Control Bestact products are manufactured in the most advanced facilities, utilizing the expertise we have gained from years of ongoing research and development as well as empirical field data under a stringent quality control system. As example of this would be our production equipment, which automatically adjusts the spring load to the optimum value, thereby maximizing contact life and reliability. Quality management on the Bestact production line Order processing, production management Parts procurement Raw materials procurement Receiving inspection Mechanical processing Automatic contact riveting Surface treatment Cleaning Drying Riveting Transportation Automatic adjustment Cleaning Adjustment Sealing Inspection Aging Sealing Shipping inspection Packing and shipping Function testing 11

12 Product lineup Wide variety of products covers market needs! Bestact control devices are ready to serve. Magnetic proximity switches Stainless anticorrosion, waterproof, non-contact actuated, magnetic proximity switch series are now in the product line. Bestact magnetically actuated proximity switches now incorporate new stainless cases. Compared to the existing aluminum die casting cases, it has improved operational reliability under harsh environments. PSMS-R3D1H-OS Anticorrosion, waterproof, separately actuated, magnetic proximity switch (Actuator: SMS-M325T-0S) PSMS-R4G1THL Columnar type magnetic proximity switch Control switches and push buttons To meet the ever-increasing demands from the market, selector switches are now offered in addition to the existing PBR type push buttons. They are providing high reliability under harsh environments. PLWG-GS34 Control switch PLRC Selector switch PBR Push button 12

13 PSKU Limit Switch Two-direction limit switch Previously, Bestact limit switches rotated only in one direction so that two left and right types were required for opposite mounting directions. By modifying the internal structure to make it bi-directional and equipping with NO/NC contacts, one type can be used for both mounting directions. PSKU-110R25C Limit Switch Main control switch This main control switch has an exceptionally long life. In addition, its contact unit is also compatible with our previous products. Bestact contact unit improves reliability significantly. PRIS Main control switch Rotary limit switch A rotary limit switch that is similar to a main control switch has Bestact contact units built-in and improves reliability significantly. The dimensions are compatible with our rotary limit switches, PCRS, PCRG and PCRV, with cam-driven contacts. PRRS Rotary limit switch 13

14 14 MEMO

15 MEMO 15

16 SAFETY PRECAUTION Although the product(s) are produced under strict quality control and should not malfunction, if there is any chance for bodily harm or property damage while in use you must apply a safety device or other necessary measure to prevent this from happening. YASKAWA CONTROLS CO., LTD. c/o Yaskawa Electric Corporation Yukuhashi Division Nishimiyaichi Yukuhashi-City, Fukuoka, Japan Phone: Fax: Overseas Sales Div. c/o Yaskawa Electric Corporation Yukuhashi Division Nishimiyaichi, Yukuhashi, Fukuoka, Japan Phone: Fax: YASKAWA CONTROLS CO.,LTD. Representative Office Europe Hauptstraße 185, Eschborn, Germany Phone: / Fax: / Yaskawa America, Inc., Switch Division 2121 Norman Drive South Waukegan IL 60085, USA Phone: Fax: The sales departments are not included nether in the QMS nor in the EMS. Contact Us(Bestact & Control Equipment Division) address : cbes@yaskawa.co.jp Homepage URL