Intelligent Ladle Tracking System (iLTS)
Tenova intelligent Ladle Tracking System is the innovative solution, engineered as modular system, dedicated to the effective management of all operations related to Ladles used in liquid steel production process, through the improvement and extension of the automatisms of supervision, control and command functions.
Overview
intelligent Ladle Tracking System is a state-of-the-art solution to provide management in ladles turnover and life.
iLTS is a modular system with independent modules that can work separately and together.
The complete solution consists of the following three modules:
- iLHS (Ladles History and Status) for registration of construction data and maintenance activities, related to ladles status and turnover, reconstructing the history
- iMILT (Minimally Invasive Ladle Tracking) for the physical identification of ladles
- iLTM (Ladles Thermal Map) for monitoring the wear conditions of the ladle refractory status, through image analysis taken with thermocameras and warning in case of critical conditions.
iLTS, through its modules, is strictly integrated with the “Manufacturing Operations Management” of iMeltShop, to whose operational choices contributes with real time information about ladles status and availability, as well as with process control systems, from which it receives information related to services in cycle (casting, steel, process data)
Technical data
Tenova intelligent Ladle History and Status realizes, in full automatic mode, the recognitions of each ladles operations, linking the ladle identification number to all ladle’s life process data along the production cycle.
The collect data are mainly related to: Details of building materials and activities, details of maintenance activities, details of process events.
All information collected are available on several reports or video pages and related to: Plant status monitoring, Service condition, Maintenance.
The main aim of the physical tracking performed by the MILT module, besides the tracing of movements and the assessing of location, is the trusty identification of the Ladles while delivering hot metal or liquid steel.
The MILT module, performing the physical identification of the ladles, is made up with SW procedures and dedicated devices. The actual adopted identification solution foresees the use of steel plates (Tag plates), welded to the Ladles, marking out for being minimally invasive and with negligible maintenance requirement, limited to an occasional renew of the coat of paint of the plates.
The purpose of Ladles Thermal Module is to monitor the wear conditions of the ladle refractory status, to warn in case of critical conditions of ladles refractory.
The thermal maps of the ladles are stored in the database of the system and are ept available for later analysis.
Innovation
The implementation of iLTS allows to obtain significant benefits in multiple areas related to different factors, such as:
- Increased efficiency in ladle management;
- Improvement of safety condition;
- Costs reduction for refractories materials and accessories;
- Cost reduction for heating gas;
- Predictive maintenance.
Safety
iLTS is dedicated to collect all data of the ladles life cycle, giving support to the personnel involved in the refractory and ladle preparation and maintenance. The wear status of refractory materials and mounted accessories is constantly kept updated and verified by "typical limits", for warning the operators when exceeding is approached. The history of ladles life allows the evaluation of consumables and equipment performances.
Automation
LHS module consists of SW application and hosting units.
Both DB engine and SW procedures run on dedicated Server or Workstation unit with Client units as User Graphic Interface.
In case of additional optional modules (MILT and/or LTM) the system resources are adequately increased.
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