Exchange solution for tilting angle monitoring

  • Direct mounting / elimination distribution gear
  • Higher accuracy
  • Easy configuration of switching points
  • Fast commissioning and restart after preset

Before: Mechanical cam limit switch and absolute encoder mounted by using an additional distribution gear.

After: Electronic position switches and absolute encoder in one unit directly mounted without distribution gear.

In steel making plants tilting angles of converters are measured by absolute encoders and monitored by mechanical cam limit switches.

The sensors are normally mounted by using an additional distribution gear, which causes mechanical play and inaccuracy. Furthermore, the mechanical cam limit switches are difficult to preset and not precise enough.

The universal encoder system U-ONE-(SAFETY-) Compact provides the same outputs as the old solution, but in just one compact and robust unit:

  • Absolute encoder
  • Electronic position switches

The unit can be mounted directly to the application shaft without using any distribution gear. For this Hübner Giessen provides special torsion resistant double-joint couplings. The switching points are easy to configure and the system can be restarted fastly after preset.

Optionally available with safety certification SIL 2 / PL d.

Robust encoders

  • Greater functional component reliability
  • Higher converter plant availability
  • More precise measurement signals despite shock and vibration loads
  • Easy and time-saving programming

Before: Old skip-car control mechanism with two mechanical geared cam limit switches.

After: More precise signals because of robust combination of bearing block and heavy duty encoders

The skip-car control mechanism utilized to date included two mechanical, geared cam limit switches that are time consuming to program. The mechanical overspeed switch utilized can prove problematical when subjected to shock and vibration loads. Neither of these components exhibits the required precision and as such are not suitable to meet the modern-day requirements of steel mill operations.

Upgrading to meet modern demands required suitable components for measuring actual values that are not only characterized by their high accuracy and functional reliability, but are also easy to program. Hübner Giessen replaced one of the geared cam limit switches with a series FG 4 K incremental encoder and an AMS 4 K type absolute encoder with integrated SSI interface. Fitting the devices to a bearing block increases their resistance to shock and vibration loads and compensates the mechanical tolerances of the installed, previous transfer gearbox. The other cam limit switch will also be replaced in a second modernizing step as will the mechanical overspeed switch be replaced by a programmable electronic overspeed switch.

In any case you can count on our support for the complete project.
From the first discussion to the installation support on site.

 

94 / Metals / Converter / Hoist
Case Studies

 

GN series motors

  • Rugged DC shunt-wound motors feature infinitely variable control
  • Designed for 20 journeys per shift (8h)
  • Short-term 3-fold overload permissible
  • Battery powered, automated guided vehicle system

Heavy-load transporters are used to transport the casting ladles from the warehouse to the casting house.

Battery powered and robust DC shunt-wound motor GN 17.17.4 for trouble-free operation without trailing cable.

Infinitely variable DC motors are required to drive a 100 ton heavy-load transport vehicle used to transport casting ladles. The motors are powered by a 48 V battery and connected to a gearbox to provide a travelling speed of 10 m / min. They must be able to provide full torque across the entire speed range combined with a possible short-term 3-fold overload capability. The vehicles are equipped with a battery (capacity 625 Ah) to provide a minimum travelling time of 200 minutes, which is calculated to provide sufficient power for 20 journeys per shift. The motor output is to be dimensioned accordingly.

For each deployed transport vehicle Johannes Hübner Giessen supplied 2 separately excited, low-voltage, shunt-wound DC motors with an integrated spring-loaded brake from its GN 17 series. The motors are equipped with an additional integrated fan to cool the outer surface and are designed for intermittent operation (S3 42 % CDF). The rated motor torque is 17 Nm. The motors are capable of delivering a short-term overload of up to 50 Nm. A BAMOBIL battery controller is included in the Hübner Giessen scope of supply to regulate power to the DC shuntwound motor.

 

88 / Metals / Casting / Ladle Transporter
Case Studies

 

Heavy-duty generator DSG P

  • Higher plant availability and productivity
  • No need to change battery (previously every 14 days)
  • Permanent power supply to the sensors ensures higher operating reliability
  • Maintenance-free and long-lasting

System structure of the self-sufficient energy supply system for the sensors of the pig iron crane.

The energy for battery charging is generated from the lifting movement of the crane by a rotating sheave at the rope pulleys.

Special safety sensors are installed in the laminated hooks to monitor if the pig iron ladles are securely attached. The sensors and a radio transmitter required to transmit the sensor signals are installed on the traversing gear of the crane system, and need to be powered by voltage of 12 VDC. Supplying power via a trailing cable is not an option, because the temperature of the pig iron in this area is about 1300 degrees Celsius. Consequently, power is supplied via a 12 V battery that is located on the traversing gear of the crane system. A solution that recharges the battery during operations is sought to avoid failures as well as downtimes resulting from the necessity to date of having to change the battery.

The permanent magnet three-phase synchronous generator DSG P 63.07.4 utilizes the rotating motion of the bull wheels of a lifting beam as a source of energy. The generator is driven via a rotating sheave and speed increasing gearbox with each lifting nd lowering motion of the crane. The generator supplies alternating voltage analogous to the speed; a rectifier converts the AC voltage to DC voltage. The charge controller monitors the charge status and the flow of energy to the battery. Implementing an autonomous auxiliary power supply in the form of well-coordinated overall solution gains valuable production time and safeguards operational reliability. The previous solution of having to change the battery every 14 days is not required any more.

 

96 / Cranes / Traversing Gear
Case Studies

 

Hot and Cold Rolling Mills

  • Easy exchange or extension of existing encoder solutions
  • Cost-efficient, as encoders can be exchanged selectively
  • Implementation in the shortest possible time, optionally SIL certified
  • Planning, delivery and mounting support from a single source

Exploded view

Exploded view

All around the world Hübner Giessen encoder solutions are installed at main drives of Hot and Cold Rolling Mills.

These large motors often run for many years and after a while the question about a possible encoder modernization arises to provide new or additional electrical outputs.

With the encoder solutions implemented by us, the scope for a modernization is limited to a minimum. For example, our FGH 6 and FGH 8 encoders have an integrated mounting flange ex works. Thereby an additional encoder can easily be added to the existing encoder system.

This could be a freely programmable overspeed switch or a universal encoder system with fi ber optic signal transmission (both optionally SIL certified). But also an additional incremental encoder with different pulse rate could be an option.

In any case you can count on our support for the complete project.
From the first discussion to the installation support on site.

Keeping an Eye on Your Equipment

August through to October is known as the windy months in South Africa. We have all born witness to the windstorms currently blowing through the country, bringing with it the much-anticipated rain and summer months.

When the weather acts up, companies in the engineering, agriculture, and mining sectors need to be more vigilant about their equipment.

Encountering a breakdown or potential injury on duty is a large concern to all involved. All equipment must be checked to ensure no potential dangers are looming.

Incidents tend to occur when we turn a blind eye to the operational aspects of a plant. This is a dangerous error to make.

It is critical to the success of any plant and the safety of its employees to run routine safety checks, ensuring that everything is running smoothly.

Mining equipment is put under duress with the workload it produces, resulting in wear and tear to all the bits and pieces keeping the plant going.

A strict maintenance schedule should be implemented to ensure that there is no downtime due to equipment failure.

Strong winds bringing dust and sand into a plant can cause damage to intricate parts of the operation that are not always visible to the naked eye.

To guide you along the safety process, we will provide you with a few tips on successfully maintaining your industrial equipment.

 

Five Tips to Successfully Maintain Your Mining Equipment

 

  • Keep machinery lubricated at all times

Any machine is destined to fail without proper lubrication. Lubrication is as important as what the moving parts of the machine are. Lubricating a machine regularly and correctly will alleviate excess friction.

The lifespan and deterioration of a machine are expedited when the correct precautions are not taken seriously and performed regularly.

 

Too much lubrication will cause errors such as energy loss, damage to seals, and an excess in the accumulation of grease.

 

Ensure that the correct type of lubrication is applied to each machine so that there are no breakdowns further down the road.

  • Clean heavy machinery well

Heavy machinery is fitted with special seals to protect the intricate parts. If dirt and grime find their way in there, the untrained eye will not detect it. This will lead to catastrophic damage and loss.

Broken or torn seals need to be changed immediately, and the breathers must be kept clean from debris. Filters need to be changed when they are dirty or clogged.

With heavy winds or rain comes dirt and grime. Keeping your machinery covered or indoors will help alleviate the trouble that this can cause.

 

  • Keep up with regular maintenance.

Conducting an inspection or repair when something goes wrong is not enough for heavy machinery to stay in top condition.

 

Set up a regular inspection plan with notations taken on any inspection performed previously.

Conduct regular checks on gaskets and seals. Belts and pulleys must also maintain their alignment.

 

Moving parts, such as gears, should be checked continually to ensure no wear and tear or damage. Proper lubrication needs to be applied to the parts to keep them functioning at optimal levels.

 

  • Take note of wear and tear.

During normal operations, you may notice some wear and tear occurring to parts or machines. It is imperative to take note of this as it may be a signal of more severe problems, especially on braking systems.

Common signs of wear and tear include heat, vibration, and belt shape.

 

Overheating can be caused by the incorrect use of lubrication to moving parts. When vibration occurs, there may be some gears or belts that are misaligned.

  • Keep the operators well trained.

One of the most effective ways to ensure your heavy machinery stays operational is to train all staff.

New employees need to go through an intense training process to ensure they know how everything works and what to look for in case of a problem.

 

Current employees should go through refresher courses and new inductions on any new and improved machines or parts that they may acquire.

 

Without the proper induction and training, any business runs the risk of downtime or even accidents that can be costly.

 

Training courses should be scheduled at regular intervals to ensure that all the operators know what they are doing and what to look for when a machine is misbehaving.

 

 

If you want to ensure the longevity of your heavy machinery, the tips above will guide you in the right direction.

 

When you need new equipment, parts, or assistance, Huebner Speed Monitoring is the partner you need. Backed with years of knowledge within the mining and agricultural industries, Huebner will ensure the safety of your workforce, and equipment is their top priority.

 

They provide each customer with a tailor-made solution. Contact one of their friendly staff today to get the ball rolling on a long and successful business partnership.

 

Storm Brakes for Safety and Efficiency: Protect your Vehicles

Being a highly technical product, many of us don’t know the first thing about industrial braking systems besides the fact that brakes stop moving objects like cars. They are a safety mechanism that could potentially be the difference between life and death – whether it be the life of a human or the operating lifespan of a machine.

Bolstering Machinery Resilience with Storm-Proof Brakes

Aside from cars, braking systems are employed in many manufacturing, mining, marine, and engineering businesses powered by heavy machinery. Continue reading as we explore industrial braking systems in further detail.

 

Back to Basics

Brakes have the sole purpose of absorbing kinetic energy when two surfaces press together to bring an object to a halt.

Functioning at high speeds with large amounts of energy coursing through them, brakes are exposed to significant wear and tear while fulfilling their purpose. They also generate a lot of heat energy as they impose stopping power.

History Lesson

Until half a century ago, braking systems were predominantly drum brakes. Drums resulted in a heat build-up inside the drum during heavy braking sessions.

As a result of the braking system being a drum, there was only one surface from which energy and heat could dissipate.

With the need for a different approach, the automotive industry decided to adopt a disc braking system in the 1970s. Disc brakes meant that the rotor was exposed to outside air when in and out of use, allowing for a more efficient cooling system.

A faster cooling system meant that the brakes were less exposed to fading and overheating challenges. Heat and energy are also dispersed over two rotors as opposed to one drum making them more effective.

In a manufacturing setting, the use of this new braking system has drastically reduced downtime with machine failures.

There has also been a marked improvement in maintenance requirements and efficiency. They have allowed operations to continue smoothly in inhospitable environments.

Now that we are all caught up on the history and the basics of braking systems let’s look at the various types of brakes you are likely to encounter.

 

Different Types of Braking Systems

 

  • Hydraulic Brakes

Most commonly used in industrial applications like mining equipment, cranes, and winches, hydraulic brakes use braking fluids to transfer pressure from the control to the brake mechanism.

 

  • Fail-safe Brakes

Power losses are a common occurrence in South Africa, making this system invaluable to manufacturing plants. Fail-safe brakes are designed to kick into effect when a power interruption happens.

 

The best example here is an elevator. A great example is the movie Speed, where the elevator cables are severed, but the Fail-safe brakes keep everyone alive by preventing a catastrophic fall.

 

  • Pneumatic Brakes

Also known as an air brake, pneumatic brakes make use of compressed air stored in a reservoir. A valve will allow compressed air to flow through and engage the brake when the lever or pedal is actuated.

 

Think about those times you are stopped at a robot, and the truck next to you gives out a loud whoosh of air. That is the brake system decompressing.

 

  • Electromagnetic Brakes

Using electromagnetic force to create friction that will employ the stopping action, these brakes are a little more advanced than most.

 

Trains, trams, and aerospace programs often make use of this technology.

 

  • Spring-Applied Brakes

Also known as power-off brakes, they work similarly to the fail-safe brakes. Spring-applied brakes will stop or hold a load if power gets cut off.

 

Hoists are an example of a product that employs this braking system.

 

  • Storm Brakes

In the event of seismic activity or massive windstorms, storm brakes ensure that cranes are not set in motion accidentally, endangering lives or causing damage.

 

Brakes are an essential part of machinery today. We often overlook their importance and the value they add to production plants worldwide.

 

They are like the unsung heroes when it comes to keeping a plant going. The breakdown of a machine can often cause lengthy production delays, costing time and money.

 

The Makeup of Brakes

Different types of brakes get made for various machines and purposes. Hence the fact that brakes are manufactured from different materials. Depending on their use, the makeup of a braking system will differ.

 

Some brakes are made out of materials that sustain moisture better and live longer, while others don’t last as long but give a smooth, gentle performance on the rotor. Some synthetic brakes are made from high-boiling point materials and do not fade as quickly.

 

The industrial market falls to ceramic brakes or semi-metallic brakes. Metallic brakes are more aggressive, cost-effective, and used for heavy-duty applications. Ceramic brakes deal better with heat and will not wear down as quickly. Ceramic brakes are also easier on the rotor.

 

Where to go for Your Industrial Brakes

When you are looking for an industrial brake supplier, Heubner Speed Monitoring has a range of brakes and solutions that ensure you have minimal downtime in machine operation.

They supply their clients with the best quality braking supplies and services, making them the ideal partner for any machine-driven enterprise.

Heubner Speed Monitoring stock braking systems such as:

  • Wheel and Gantry Brakes
  • Drum and Band Brakes
  • Disc Brakes
  • Motor Mounted Brakes

Their goal is not to become your local brake stockist but instead to couple with you as your partner in business, providing solutions and products that you can rely on.