See all Blog Posts How is Automation Used in the Steel Industry? Category: Aluminum, Stainless Steel, Steel Posted: October 8, 2024 As far back as the early 1800’s, engineers were programming machines using cardboard sheets with holes punched into them, to automate the weaving process. In more recent times, automation has become more prolific, refined and efficient. One industry impacted by automation is steel production, with its long startup times and potentially dangerous working conditions, It sounds like an ideal use case. But how exactly is it used? What is Industrial Automation? The first thing that comes to mind for most when considering automation are robots; the large orange mechanical arm-looking devices often seen assembling cars. Whilst these are a valuable tool, there are other automation tools that engineers deploy across many industries. Process Control Any precision process, such as making steel, will have many sensors and quality control checks before the product is completed. Anything from thickness, heat, and even chemical composition can be continuously monitored. One invaluable use of automation is having a processor that is able to monitor the readings of such sensors, check if they are acceptable, and adjust or even halt the production line accordingly. This allows automated operation, and removes the need for, and potential errors of, a human doing the same task. Robotics Manufacturing robots are also heavily utilized, being involved in operations such as material strapping, marking and handling. In addition to the robot arm type robots capable of complex motions, robotic logistics is widely used too, usually involving tram-like robots running on rails. This can be as simple as a transport vehicle following a set path through a space, through to full scale, process wide automation of raw material handling, product storage and distribution. Applications of Automation in the steel making industry Parameter monitoring and process adjustment – Automation of process improvement aids long term evidence-based improvements to the product Quality control – with sensors detecting both dimensional and chemical properties, the process of ensuring the end product is within tolerance is almost instant, enabling swift alterations and thus reducing wastage Marking of partly finished and finished product – stamping, printing or engraving of the end product is needed for traceability. Linking this to a central database improves accuracy and efficiency Packaging such as strapping or wrapping – this can often involve working around large, unwieldy objects such as coils of sheet steel, robots remove the risk of injury to workers should something go wrong Deburring or dross cleaning – a tedious, time consuming and hazardous job, automation is ideal for increasing quality and speed Welding of tube and coil – another ideal task for automation, the welding of long, straight tubes is easily achieved with a robotic welder on a precision track The Effect of Automation in the Steel Production Industry As with any industry that has taken advantage of it, automation has revolutionized the steel industry. In many ways the processes involved lend themselves well to using automation, with repetitive tasks, harsh working conditions and continuous manufacturing. One of the biggest improvements is in quality control. With the constant stream of data, processes can be monitored over time, and with changes to said processes being automated, a continuous feedback system is easy to establish. One of the challenges of automating any process is safety. The type of robots needed to maneuver and work steel products tend to be incredibly powerful, and fast, meaning humans must keep their distance. Systems such as interlocks and light-guards are used to ensure worker safety. On the other hand, with the process of making steel products involving extremely high temperatures and extremely heavy components, removing humans from the work area in lieu of robots, results in a net increase in safety. Further improvements are being made thanks to the ability of automation being able to run 24/7, something that reduces wastage and energy costs as the furnaces and rolling processes take thousands of watts of energy to bring up to temperature. Pros and Cons of Automation in the Steel Industry Advantages of Automation in Making Steel Products Increased quality control through faster processing and fewer errors Higher efficiency, due to less downtime Faster operations, resulting in more output Reduction of risk to workers Reduction in environmental impact through higher efficiency Disadvantages of Automation in Making Steel Products Fewer jobs for local people High upfront costs Higher maintenance costs Less operational flexibility due to setting programs and procedures More safety zoning and procedures are required to keep workers safe Steel For Your Projects Whether you’re manufacturing steel products or just working on a simple home automation system such as self-opening gates, we have the metals needed to get your project off the ground. 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