In the aluminum industry, intelligent manufacturing concepts are increasingly moving into the spotlight. Customers are pursuing personalized strategies to exploit the potential of state-of-the-art technologies to satisfy their specific needs. When it comes to autonomous plant operation, it is not just IT systems that are crucial here: designing and enhancing autonomous plant technology is equally important.
That is why highly automated solutions that maximize both efficiency and safety in industrial production play a central role at SMS group. Machines and systems must not only be integrated but also have the capability to act independently and adapt dynamically to changing production requirements.
Automated processes: A new level of aluminum rolling equipment
Automatic coil destrapping
Fully automatic destrapping units, used in aluminum rolling mills, are one example of this. The application uses intelligent sensors that detect the aluminum coil. A robot with a cutting tool then removes the tying straps in a fully automatic process. In the past, operating crew members had to perform these steps manually; today, these fully automatic systems are used in SMS facilities around the world.
Automatic strip threading
Another innovation is the system used for automatic product threading into the rolling mill stands. Previously, the guide tables had to be adjusted manually to ensure precise guidance of the head end of the strip into the roll gap. Now, thanks to its optimized mechanical design and intelligent automation, the X-Pact® Threading Assistant can detect the position of the coil and automatically adjust the head end. This eliminates the need for manual operator intervention, which not only saves time but also increases the availability of the plant. Over the course of a production year, these time savings add up, meaning significantly higher plant availability and thus increased annual productivity.
Automated rolling process stability with X-Pact® Sense
Another central objective of the automation system is to enhance the stability of the rolling processes. This is where AI-assisted sensors are used, which precisely detect any off-center strip runout in the mill stand. Such deviations can cause asymmetries in the roll gap and impair the quality of the final product. With its high-precision detection and automatic response capabilities, SMS group’s X-Pact® Sense technology ensures that the rolling conditions remain constant every time, from one product to the next. The automation system responds with an automatic leveling system that keeps the strip in the correct center position. X-Pact® Centerline Control is an integrated solution that not only ensures uniform strip guidance, but also significantly reduces the need for manual intervention. This enhances efficiency and guarantees consistent production quality.
Automated intermediate cropping
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.
Telescopic measurements for coiling accuracy
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.
Reliable and precise flatness measuring and control systems
SMS group has successfully developed a concept for integrating X-Shape flatness measuring rolls into the process technology of hot rolling applications. This latest generation of the flatness measuring and control system reliably and precisely meets all high quality demands for high-end strip. It measures the actual flatness of the strip by taking into account the strip tension and the rolling speed. This precise measurement data is used as key input variables for the flatness control system and guarantees first-rate quality monitoring. The implementation of the X-ShapeHot technology ensures that the products meet the highest standards and that the efficiency of the rolling process is optimized.
Rolling process efficiency and cost effectiveness
The X-Pact® Flying Gauge Control is an advanced technological solution designed specifically to optimize the rolling process. Especially for thicker material thicknesses, this function significantly shortens the scrap length by reducing the impact of tail creases on the strip surface. Moreover, the thickness at the head end of the strip is 5 to 10 percent lower, so the input material can be used more efficiently. For thinner material target thicknesses, the benefits of the system are clear: greater process stability due to optimized strip threading and a tail-out process without additional scrap.
Intelligent strip production: New potential and maximum individuality
Advanced digital tools to maximize transparency, process reliability, and maintenance efficiency are a key component of intelligent strip production. DataXpert includes expert systems that combine rule-based approaches with artificial intelligence to monitor the plant’s status in real time, detect anomalies, and suggest what immediate action to take.
DataXpert and the Genius CM® condition monitoring system work in perfect harmony with each other. This modular system consistently monitors the process data from the equipment and continuously provides information on the condition of the components. Users receive real-time alerts so they can take action right away. Genius CM® takes quality and availability to a completely new level by enabling continuous condition evaluation.
State-of-the-art aluminum plants from SMS group generate an enormous amount of data that serve as the basis for innovative digital solutions. This treasure trove of data opens up a whole new world of possibilities with regard to automation and efficiency. Tools such as DataXpert and Genius CM® convert this data into actionable information that optimizes operations while minimizing human intervention at the same time.
Plant owner and SMS group are driving the transformation together
Maximum transparency is achieved by integrating advanced data management and digital control systems. These systems create closed control loops that improve the stability of processes and help operators to make appropriate decisions. At the same time, this approach enables plant owners to sharpen their focus on strategic objectives and their core business. Unlike before, they are no longer heavily occupied and bound by operational details. It is not so much about replacing the entire workforce, but rather maximizing the productivity and availability of the plants and equipment. Autonomous systems are designed to operate 24/7 with minimal downtimes and maximum efficiency.
The path to the autonomous aluminum plant, however, is not only a question of technology but also of cultural change among plant owners. A willingness to transform and to collaborate in close partnerships is fundamental to this. SMS group is ready to keep pursuing this path. The vision becomes more tangible with every new plant that is put into operation. The journey is far from over, but the direction is clear: Continuing the course towards more productive, flexible, and sustainable production in the aluminum industry.