Case Study:
Complete Electrical Retrofit
Steel Service Center Struggling with Obsolete Systems Receives Complete Electrical Retrofit.
Objective
- Conduct annual maintenance on various equipment,including breakers and switches
- Use secondary injectors, Megger and Ductor for trip unit functionality and equipment phase integrity
- Address and resolve issues like trip unit failures, broken charging switch, and tripping problems
- Thoroughly clean equipment post-testing
- Extract oil samples from 6 transformers for comprehensive testing
Solutions
- Calculated the complex algorithm for electronic camming functionality due to missing schematics and descriptions.
- Integrated new drives, motors, and controls into the existing line.
- Integrated remote monitoring equipment and software so the Quad Plus diagnostics team could assist with future problems within one hour.
- Utilized muting zones in lieu of gates and fences and lowered control voltages to provide a safer work environment.
- Supplied customers with spares for all new systems to eliminate lengthy downtime in the event of a part failure.
- Provided the customer with detailed documentation, including a detailed PLC program with comments and AUTOCAD electrical and mechanical prints.
Results and Benefits
- The customer no longer has to worry about a weekslong disruption to their production line in the event of failure.
- The customer now enjoys a well-documented system, including prints and schematics, to make future improvements or repairs easier and safer.
- Improved line accuracy which allows the customer’s line to operate at a higher speed and therefore increased their monthly sales potential.
- Improved safety measures for a safer work environment for maintenance and production staff.
Background
The Quad Plus Gauging Team received a call from a cold rolling mill customer experiencing problems with their single point scanning system. Along with limited capabilities, the existing scanner was slow to update. The old system also did not offer any automatic controls and instead relied on operator interaction to control the profile of the product.
Quad Plus Solution
The first part of the solution was to provide the customers with a full-sheet scanning triangulation laser system. The new system will allow a thickness measurement across the full sheet and with faster update times. The second part of our solution was to integrate the new scanning system into their existing control system. This allowed us to implement an automatic gauge control that would adjust the machine automatically to create a superior product, and to complete the process faster than a manual operator could.
The final result was a revamped system that produces a flatter product with tighter tolerances delivered more consistently. Along with reducing production costs with better controls, the new system is less reliant on a human operator which allows for more efficient operations.
Investing in Your Future
When you’re ready to upgrade and update your industrial equipment but worried about the cost or disruption, we can help. Our solutions are designed to make your operations more efficient and reliable, so your investments pay for themselves over time.
When you’re ready to enjoy faster production, tighter tolerances, and the benefits of an automated system, we’re ready. The Quad Plus team has decades of experience in nearly every industry, including yours.
