The new line is designed to produce 400,000 tons per year of exposed automotive steels, meeting the highest surface quality requirements. SMS group supplied everything out of one hand: comprehensive mechanical, furnace, and process equipment, along with electrical and automation systems, while also providing technical support during the erection and commissioning phases.
The CGL is engineered to ensure consistent surface quality from strip entry to recoiling. The cleaning section combines mechanical, hydrodynamic and chemical treatment steps to effectively remove surface contamination, preparing the strip for subsequent thermal treatment. The technological centerpiece of the line is the Drever all-radiant tube annealing furnace, which maintains surface integrity and tight material tolerances by controlling the furnace atmosphere independently from combustion and ambient conditions. After cleaning, annealing and galvanizing, the Duma‑Bandzink air‑knife system ensures a uniform zinc layer and optimized surface quality, which are critical aspects for exposed grades. The inline skin‑pass mill applies a controlled surface imprint and improves strip shape, which supports subsequent forming operations. This process enhances surface finish and ensures that the steel sheets meet the automotive industry's stringent requirements.
Intelligent production according to X-Pact® Lights-Out concept for autonomous plant operation
The automation solution provides precise tension and elongation control, improving process accuracy. In addition to full X-Pact® level 1 and level 2 automation, the scope of supply includes technological measuring devices and smart sensors to maximize efficiency and process stability, supporting highly automated line operation.
Intelligent production of the hot‑dip galvanizing line is achieved through SMS group’s X‑Pact® Lights‑Out concept for autonomous plant operation. At the core of this concept is the X‑Pact® Integrated Operating Center (IOC) featuring large screens and line-mounted cameras for integrated monitoring and control from a single operator room. X-Pact® Vision HMI, interacting with live video streams, gives the operator a clear, real‑time view of line status and improves operational efficiency.
The system architecture combines on‑site video acquisition, distributed seat management, and a central control system with virtualized HMIs and level 2 servers operating in a redundant cluster for high availability. Network cameras positioned along the production line transmit high‑resolution video signals to the IOC, while the seat management system integrates audio and video switching, remote KVM, and collaboration functions. Automatic screen pushing ensures that the most relevant views appear instantly where needed. Based on PLC events and alarms, the system automatically combines camera feeds and HMI outputs, displaying them on operator monitors or the big screen wall. Video sequences are recorded with searchable labels such as time and material number, enabling rapid playback and root‑cause analysis.
AI enabled visual inspection and automatic detection
Artificial intelligence further enhances production reliability through automated visual inspection and abnormality detection. The system incorporates intelligent cameras and visual recognition algorithms to replace manual checks and ensure consistent quality:
- Coil side defect detection: Identifies telescope, overflow edge, and collapse; rejects coils with severe defects
- Strip threading stacking detection: Monitors entry and exit sections during threading and tailing; alarms within 1 second of detection
- Core pulling monitoring: Detects abnormal core‑pulling (>20 mm) and triggers alarms within 1 second, linked to level 1 automation
These features reduce operator workload, improve safety, and guarantee uniform quality for high‑value automotive grades.
Our new integrated operating center has transformed the way we manage production. This centralized approach allows us to optimize the entire line from a single control station, improving efficiency, reducing operators (from 9 to 5), and ensuring consistently high product quality. It is a major step toward autonomous operation and plays a crucial role in achieving higher yield for exposed automotive grades.
Focused execution
Prior to delivery, the automation system was installed, tested and optimized as part of the X-Pact® Plug & Work integration test to enable efficient commissioning. This end-to-end testing of major control functions before shipment significantly reduced commissioning time and helped the customer achieve the first-coil milestone, supporting a rapid and smooth start-up.
The achievement of the first coil production 40 days ahead of schedule highlights the effective collaboration and strong teamwork between the project teams of Angang and SMS group, validating the chosen project execution approach.
With CGL No. 2 now producing at the site, Angang Guangzhou Automotive Steel is well-positioned to meet the market demand for exposed automotive grades, delivering steel sheets with optimal surface consistency and quality. The early start‑up reflects the strong teamwork of both companies and demonstrates SMS group’s ability to deliver complex, modular plants with effective digital integration and lifecycle support.