Case Study

Dynamic system to operate routes in a raw material yard

The challenge of building a flexible, intuitive system that would prevent contamination of materials on routes

Steel & Metal

Projects and solutions for the entire steel production chain

Project Data

VERSATILITY

+40

conveyor belts

High number of belts to meet various transport possibilities and types of materials

FLEXIBILITY

Infinite

route possibilities

The belts are able to meet any configuration for the 15 origins and 13 destinations

DYNAMICS

Intuitivity

in route construction

Intuitive system for setting up a new route or using an existing one

Context and Challenges

A large steel mill needed to develop a system to manage routes in its raw material yard. The system needed to be dynamic and intuitive. Being responsible for supplying areas such as coke oven, sintering and blast furnace, the yard was fundamental in logistics, key to production efficiency. There was also the safety aspect: there could be no contamination of the materials under any circumstances, and there were several possible routes. The system was to meet the following challenges:

  1. Set routes with ease and, when necessary, reuse them
  2. Allowing the configured routes to be dynamic, as the complexity of production made it unfeasible for them to be static
  3. Track materials on conveyor belts to ensure they are non-contaminated
  4. Provide a mass balance per stack and per route available in the supervisory system (level 1)
  5. Provide a history of material allocation in the stacks since startup
  6. Have high availability, to ensure the operation and storage of these movements

Solutions Used and Equipment Provided

We use an Oracle Cluster to ensure high availability of the relational database.

We have made the indexed programming of the PLCs, using only the seniority of IHM Stefanini, in order to control the drives of the conveyor belts, where the sequence and interlocks are dynamically changed when changing a route.

We have made a complex and careful programming of data movements, through the level 1 system, to ensure the correct mass balance and all its history.

The tracking of materials on conveyor belts was developed using calculations, as there were constantly problems when using sensors.

Many, many tests have been carried out to ensure the safety of the entire solution and the non-contamination of materials. Endless ways of setting routes.

Experts

Process Control Engineer

Henrique Diniz Rocha

Full Stack Data Scientist

Pablo Drumond

Awards

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Dynamic system to operate routes in a raw material yard

The challenge of building a flexible, intuitive system that would prevent contamination of materials on routes

January 25, 2021

published by

Process Control Engineer

Henrique Diniz Rocha

published by

Full Stack Data Scientist

Pablo Drumond

VERSATILITY

+40

conveyor belts

High number of belts to meet various transport possibilities and types of materials

FLEXIBILITY

Infinite

route possibilities

The belts are able to meet any configuration for the 15 origins and 13 destinations

DYNAMICS

Intuitivity

in route construction

Intuitive system for setting up a new route or using an existing one

A large steel mill needed to develop a system to manage routes in its raw material yard. The system needed to be dynamic and intuitive. Being responsible for supplying areas such as coke oven, sintering and blast furnace, the yard was fundamental in logistics, key to production efficiency. There was also the safety aspect: there could be no contamination of the materials under any circumstances, and there were several possible routes. The system was to meet the following challenges:

  1. Set routes with ease and, when necessary, reuse them
  2. Allowing the configured routes to be dynamic, as the complexity of production made it unfeasible for them to be static
  3. Track materials on conveyor belts to ensure they are non-contaminated
  4. Provide a mass balance per stack and per route available in the supervisory system (level 1)
  5. Provide a history of material allocation in the stacks since startup
  6. Have high availability, to ensure the operation and storage of these movements

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