X‑Pact® Sense  integrates AI‑assisted sensors and cameras systems to capture and evaluate process data in real time. It processes visual, acoustic, and haptic signals using advanced algorithms to detect abnormalities and ensure consistent product quality. 

Compact units integrate sensing, evaluation, recording, and communication functions, enabling fast and targeted data transfer to automation systems. 

Automated visual inspection reduces manual intervention while increasing process stability and repeatability. Designed for demanding environments, the product family X-Pact Sense® enhances operational safety and enables more efficient and flexible production.

Customer challenges addressed

  • Integrated sensing, analysis, and communication in one unit
  • Designed for high temperatures and harsh conditions
  • Improved process stability through continuous monitoring
  • Automated visual inspection and real-time abnormality detection within milliseconds
  • Reduced manual inspection workload, improved safety
  • Consistent quality for high-value material grades

Key features

Integrated strip guidance​ at finishing mill

Camera system detects the strip edges in harsh environment; a closed-loop algorithm calculates any deviation from the strip centerline and provides a levelling correction signal for the mill stands​.

Automatic slab turning​ at plate mill

An automatic slab turning system leveraging advanced camera recognition to replace manual visual inspection. A high‑resolution camera installed in the slab turning area precisely detects slab position and turning angle. Real-time signals are transmitted to the mill’s Level 1 system, which controls the roller table to enable fully automated slab turning.

Automated intermediate cropping​ at alluminum rolling mill

In aluminum hot rolling mills, where ‘alligatoring’ is a common problem, the X-Pact® Alligator Measurement system boasts a comprehensive range of benefits. The length of the alligator defect at the head end and tail end of the strip is measured automatically, with intermediate cropping subsequently optimized by precisely positioning the strip at the shear without any further manual input by the operator. The result is a significant reduction in downtimes and improved overall efficiency.

Coil side defect detection at hot‑dip galvanizing line

Camera system identifies telescope, overflow edge, and collapse​. The system rejects coils with severe defects​

Strip threading stacking detection​ at hot‑dip galvanizing line

The intelligent system monitors entry and exit sections during threading and tailing;​ alarms within 1 second of detection.

Core pulling monitoring​ at hot‑dip galvanizing line

The system detects abnormal core pulling (>20 mm) and triggers alarms within 1 second​; linked to level 1 automation​ ​

Telescopic measurements for coiling accuracy at alluminum rolling mill

To achieve the desired quality of the finished coil, the coil structure (telescopicity) and the offset between the individual windings play a vital role. The data collected by the 3D lasers is analyzed and used for automated quality control. If the coil does not run through properly and the desired structure is not achieved, the X-Pact® Telescopic Measurement system can correct the strip travel using the measured values recorded and evaluated online in a closed control loop.

X-Pact Sense - Video