Faculty of Engineering – Cairo University

Mechanical Design and Production Engineering

Graduation Project Report
2021

Anton Tamer Shafique Abdel-Sayed

Ayman Hisham Mahmoud Ahmed
Mahmoud Ahmed El-Sayed Kassab
Hager Ali Mahmoud Ali

Dr. Antoine Dimitri

 In all the latent meanings of humbleness and gratefulness, we would like to acknowledge
our profound gratitude to all those who have helped us to put together these ideas, and to elaborate
them well above the level of simplicity and into something concrete. Firstly, we would like to
express our special and endless thanks to our project supervisor

Dr. Antoine Dimitri

Assistant Professor at the Mechanical Design and Production Department,
Faculty of Engineering, Cairo University

This project would not have seen the light if it were not for the support of so many people
who never hesitated to provide advice and guidance to us. This group of people represents EL
MARAKBY STEEL

Mr. Mostafa Rashad

Rolling Mill Plant Manager at El MARAKBY Steel

Mr. Ramadan El-Sherbiny

Chief Engineer of the Electric Team

Mr. Mostafa Abdel-Mohsen

Automatic and Control Engineer

This work is not a fruit of a moment. It has been developed over a year of constant and
intense effort under the sponsorship and the technical supervision of SIEMENS Co. as it was
supervised by

Mr. Sherif El-Naggar

Head of Customer Service & Training - Digital Industries Siemens

Mr. Abdelrahman Maged Badrawy

Field Services Engineer at Siemens

I
 This project aims to upgrade the roughing operation performed on a three-high rolling
stand, which operates in a production line used to produce steel rebars. This operation is run
manually, while the rest of the production line is automated. The main problems in the operation
are inconstant production rate, and time and energy wastes. For stabilizing the production rate, as
well as establishing constant working times for mechanical and electric equipment, an automated
system is developed using a PLC and a set of sensors. And for reducing the waste in energy and
time, a mechanism is designed to change the direction of the billet between consequent rolling hits
with minimal waste. The automated system is implemented and tested, showing great results in
stabilizing the process production rate. Moreover, the modified automated system has minimal idle
time for the motors used in the process. As for the stopper mechanism, studies are made to prove
its efficiency and how it affects the production, which gives it great opportunity for installation in
the future to enhance the process.

II
Acknowledgement I
Summary II
Table of Contents III
List of Figures VI
List of Tables IX
Abstract X
Introduction 1
Chapter One: Project Introduction 3
1.1 MKS Group 3
1.2 Description of Roughing Sector 4
Rolling Stand and Line Description 4
Labeling of Furnace, Lines and Stand Manual Control 7
Electric Panels 8
Chapter Two: Project Study 11
2.1 Problem Definition 11
2.2 Objective of the Project 12
2.3 Rougher Sector Current Layout 13
2.4 Production Line Study 14
Trend Analysis 14
Time Analysis 16
2.5 Idea Generation 17
2.6 General Approaches 18
2.7 Contributing Parties and Project Steps 19
Project Parties Contacts, Responsibilities 19
Project Steps 20
2.8 Detailed Approaches 21
Electric Sensors Approach 21
Electromechanical Approach (SKF Bearing Encoder) 28
Mechanical Approach (Mechanical Detectors) 31
Approaches Comparison 43

III
 Table of Contents
Chapter Three: Stopper Mechanism 46
3.1 Spring Design on Basis of Dynamic Impact Simulation 46
3.2 First Method (Adams Impact Simulation) 47
General Parameters of The Simulation Model 48
Results of the Simulation 49
3.3 Second Method (SolidWorks Motion Analysis) 53
Result of the Simulation 54
3.4 Third Method (MITCalc Spring Design) 55
Operating Conditions 55
Material and Working Conditions 55
Final Results of The Design 56
Summary of MITCalc Spring Design 56
3.5 Online Calculator 57
Summary of Calculator Spring Design 57
3.6 Fourth Method (MATLAB Simulation and SIMSCAPE) 58
MATLAB Simulation 58
SIMSCAPE Simulation 61
Firstly (During Impact) 61
3.7 Governing Equations 65
Impact Analysis 65
Spring stiffness 65
3.8 Summary Results of Spring Design 66
3.9 Operation Conditions 67
3.10 Stopper Mechanism Overview 68
3.11 Stopper Mechanism Components 69
3.12 Stopper Mechanism Design Illustration 70
3.13 Stopper Mechanism Assembly and Components Working Drawing 72
3.14 Stopper Mechanism Production Chart 83
3.14 Stopper Mechanism Simulation 84
Dynamic Simulation 84
Static Simulation 87

IV
 Table of Contents
Chapter Four: Automation 92
4.1 Flowchart of the Automated System 92
Process Explanation 92
List of Inputs and Outputs 92
Block Diagram 93
Start 94
Counter Function 95
Motors Conditions 97
4.2 Layout After Automation 101
4.3 Automatic System Implementation 102
4.4 Explanation of Human Machine Interface 107
Control Type 107
Observation Type 110
Statistics Type 114
Test Type 115
4.5 Comparison of manual and automatic system 116
First: Manual System 116
Second: Automatic System 116
Results 117
Conclusion 119
Recommendations 120
References 121
Appendixes 122
Appendix (A) – PLC Program 122

V
FIGURE 1: STAND FRONT VIEW 4
FIGURE 2: STAND SIDE VIEW 4
FIGURE 3: BEFORE STAND LINE DEFINITION 6
FIGURE 4: AFTER STAND LINE DEFINITION 6
FIGURE 5: TOP VIEW ILLUSTRATION OF THE STAND, FURNACE AND LINES 6
FIGURE 6: CONTROL PANEL OF THE FURNACE 7
FIGURE 7: CONTROL PANEL OF TEMP CONTROLLERS IN FURNACE 7
FIGURE 8: LEFT CONTROL PANEL OF THE STAND 7
FIGURE 9: RIGHT CONTROL PANEL OF THE STAND 7
FIGURE 10: THE USED RELAYS 8
FIGURE 11: HIGH TORQUE MOTORS CONTACTORS 8
FIGURE 12: THE WHOLE ELECTRIC PANEL OF POWER SOURCE FOR MOTORS 8
FIGURE 13: THE USED INVERTERS 8
FIGURE 14: PANEL OF THE FURNACE MOTORS 9
FIGURE 15: LINE 6 CONTACTORS 9
FIGURE 16: HIGH TORQUE MOTORS CIRCUIT BREAKERS 9
FIGURE 17: LAYOUT BEFORE AUTOMATION 13
FIGURE 18: THE TREND OF STAND MOTOR 14
FIGURE 19: THE GENERATED GRAPH FROM EXCEL 15
FIGURE 20: TRACING OF THE GRAPH 15
FIGURE 21: EFFECT OF WAVELENGTH ON BOTH PHOTON AND THERMAL DETECTORS 21
FIGURE 22: PROXIMITY SENSOR 22
FIGURE 23: PROXIMITY SENSOR SPECS 22
FIGURE 24: CONNECTION AND WIRING 22
FIGURE 25: DIMENSIONS 22
FIGURE 26: INFRARED PHOTODETECTOR DANIELI 24
FIGURE 27: DIVERSION OF DETECTION RANGE 24
FIGURE 28: COMMUNICATION BOX SPECS. 26
FIGURE 29: COMMUNICATION BOX 26
FIGURE 30: COMMUNICATION BOX DIMENSIONS 26
FIGURE 31: SENSING HEAD 27
FIGURE 32: SENSING HEAD DIMENSIONS 27
FIGURE 33: ASSEMBLY OF COMMUNICATION BOX AND SENSING HEAD 27
FIGURE 34: DIFFERENT D.S (DISTANCE TO SPOT) EXPLANATION 27
FIGURE 35: SKF BEARING ENCODER 28
FIGURE 36: DATA AVAILABLE FOR SKF BEARING ENCODER 30
FIGURE 37: PROXIMITY SENSOR EXPOSED TO HIGH TEMPERATURE 31
FIGURE 38: EXTREME OPERATION CONDITIONS FOR SENSORS 31
FIGURE 39: FIRST ATTEMPT MECHANISM 31
FIGURE 40: SECTION OF FIRST MECHANISM 32
FIGURE 41: FRONT VIEW OF FIRST MECHANISM 32
FIGURE 42: ISOMETRIC VIEW OF FIRST MECHANISM 32
FIGURE 43: FIRST MECHANISM COMPONENTS 33
FIGURE 44: MECHANISM HOOKS AND SENSOR HOUSING 33
FIGURE 45: MECHANISM RUBBER SLEEVES AND SLOTTED BRACKETS 33
FIGURE 46: MECHANISM SPRING ELEMENT 33

VI
 List of Figures
FIGURE 47: DIRECTION OF AXIAL FORCE ACTING ON FIRST MECHANISM 34
FIGURE 48: AXIAL FORCE ILLUSTRATION 35
FIGURE 49: SECOND MECHANISM 35
FIGURE 50: SECTION OF SECOND MECHANISM 36
FIGURE 51: FRONT VIEW OF SECOND MECHANISM 36
FIGURE 52: ISOMETRIC VIEW OF SECOND MECHANISM 36
FIGURE 53: SECOND MECHANISM COMPONENTS 37
FIGURE 54: RUBBER RESISTANCE 37
FIGURE 55: BEARING HOUSING AND CAM PROFILE 37
FIGURE 56: ADAMS DYNAMIC MODEL BEFORE HIT 38
FIGURE 57: ADAMS DYNAMIC MODEL DURING 38
FIGURE 58: SPRING ANGLES BEHAVIOR VS TIME 39
FIGURE 59: TORQUE APPLIED TO SPRING VS TIME 40
FIGURE 60: SPRING OPERATING CONDITIONS 41
FIGURE 61: SPRING MATERIAL AND WORKING CONDITIONS 41
FIGURE 62: MITCALC RESULTS 42
FIGURE 63: ADAMS DYNAMIC MODEL BEFORE HITTING 47
FIGURE 64: BILLET POSITION AFTER HIT THE WALL 47
FIGURE 65: BILLET POSITION AFTER HIT THE SPRING 48
FIGURE 66: BILLET VELOCITY VS TIME 49
FIGURE 67: BILLET VELOCITY VS TIME 50
FIGURE 68: SPRING FORCES VS TIME 52
FIGURE 69: SPRING DEFLECTION VS TIME 52
FIGURE 70: SOLIDWORKS DYNAMIC MODEL 53
FIGURE 71: SOLIDWORKS SIMULATION RESULTS 54
FIGURE 72: SPRING OPERATING CONDITIONS 55
FIGURE 73: SPRING MATERIAL AND WORKING CONDITIONS 55
FIGURE 74: MITCALC SPRING DESIGN RESULTS 56
FIGURE 75: ONLINE CALCULATOR SPRING MATERIAL AND MASS PROPERTIES 57
FIGURE 76: ONLINE CALCULATOR SPRING DIMENSIONS 57
FIGURE 77: SPRING DEFLECTION VS TIME UNDER C =0N.S/M Ζ = 0 58
FIGURE 78: SPRING DEFLECTION VS TIME UNDER C =1917N.S/M Ζ =.1 59
FIGURE 79: SPRING DEFLECTION VS TIME UNDER C =396N.S/M Ζ =.02 59
FIGURE 80: SPRING DEFLECTION VS TIME UNDER C =0N.S/M Ζ =0 60
FIGURE 81: SPRING DEFLECTION VS TIME UNDER C =396N.S/M Ζ =.1815 60
FIGURE 82: SIMSCAPE MODEL 61
FIGURE 83: SPRING DEFLECTION VS TIME UNDER C =0N.S/M Ζ =0 61
FIGURE 84: SPRING DEFLECTION VS TIME UNDER C =1917N.S/M Ζ =.1 62
FIGURE 85: SPRING DEFLECTION VS TIME UNDER C =396N.S/M Ζ =.02 62
FIGURE 86: SPRING DEFLECTION VS TIME UNDER C =0N.S/M Ζ =0 63
FIGURE 87: SPRING DEFLECTION VS TIME UNDER C =396N.S/M Ζ =.1815 63
FIGURE 88: SPRING DEFLECTION VS TIME 64
FIGURE 89: SPRING VELOCITY VS TIME 64
FIGURE 90: SPRING CONSTANT VS TEMPERATURE 67
FIGURE 91: MECHANISM ISOMETRIC VIEWS IN NEUTRAL CONDITION 68
FIGURE 92: MECHANISM ISOMETRIC VIEW IN WORKING CONDITION 68
FIGURE 93: STOPPER MECHANISM COMPONENTS 69
FIGURE 94: ILLUSTRATION OF LINE 2, 4 AND 6 70
FIGURE 95: LINE 2 AND 4 AFTER MODIFICATION 70

VII
 List of Figures
FIGURE 96: STOPPER ASSEMBLY WITH THE BED 70
FIGURE 97: FIXED PLATE FIXATION WITH THE BED 70
FIGURE 98: IMPACT PLATE ASSEMBLY WITH THE STOPPER 71
FIGURE 99: SPRING CUPS FIXATION WITH THE PLATES 71
FIGURE 100: THE PULLEYS AND THEIR SUPPORTING SHAFT 71
FIGURE 101: ADAMS IMPACT FORCE VS TIME 84
FIGURE 102: PROPERTIES OF NONLINEAR-DYNAMIC SIMULATION 84
FIGURE 103: STRESSES APPLIED ON THE IMPACT PLATE 85
FIGURE 104: MAXIMUM STRESS REGIONS ON THE IMPACT PLATE 85
FIGURE 105: PROPERTIES OF NONLINEAR-DYNAMIC SIMULATION 86
FIGURE 106: ADMAS IMPACT VELOCITY VS TIME 86
FIGURE 107: SOLIDWORKS SIMULATION MESH ON THE PINS 86
FIGURE 108: STRESSES APPLIED ON THE PINS 87
FIGURE 109: FIXED PLATE SIMULATION FIXATION AND THE APPLIED FORCE 87
FIGURE 110: STRESSES APPLIED ON THE FIXED PLATE 88
FIGURE 111: FIXED PLATE FACTOR OF SAFETY DISTRIBUTION 88
FIGURE 112: ROD SIMULATION FIXATION AND APPLIED LOAD 88
FIGURE 113: STRESSES APPLIED ON ROD 89
FIGURE 114: ROD FACTOR OF SAFETY DISTRIBUTION 89
FIGURE 115: SHAFT SIMULATION FIXATION AND APPLIED LOAD 89
FIGURE 116: STRESSES APPLIED ON THE SHAFT 90
FIGURE 117: SHAFT FACTOR OF SAFETY DISTRIBUTION 90
FIGURE 118: BLOCK DIAGRAM OF THE AUTOMATED SYSTEM 93
FIGURE 119: THE LAYOUT AFTER AUTOMATION 101
FIGURE 120: TEMPERATURE SENSOR AFTER FURNACE 102
FIGURE 121: HOT METAL DETECTOR ON LINE 1 102
FIGURE 122: TEMPERATURE SENSOR BEFORE THE ROUGHER 103
FIGURE 123: TEMPERATURE SENSOR AFTER THE ROUGHER 103
FIGURE 124: HOT METAL DETECTOR FOR LINE 2 AND 4 104
FIGURE 125: HOUSING OF HOT METAL DETECTOR ON LINE 6 104
FIGURE 126: HOT METAL DETECTOR ON LINE 6 104
FIGURE 127: THE ELECTRIC PANEL OF THE AUTOMATED SYSTEM 105
FIGURE 128: CONTROL PAGE 107
FIGURE 129: CONTROL PAGE WITH CHANGES 109
FIGURE 130: CONTROL PAGE AFTER PRESSING THE ERRORS AND MODE 2 CANCELLATION BUTTONS 110
FIGURE 131: SENSORS PAGE 110
FIGURE 132: ERROR DUE TO BILLET'S TEMPERATURE WHICH RECEDES THE LOWER VALUE 111
FIGURE 133: SENSORS PAGE DURING OPERATION 111
FIGURE 135: SIGNAL FOR THE BILLET THAT EXCEEDED THE UPPER TEMPERATURE VALUE 112
FIGURE 134: ROUGHING LINE LAYOUT WHILE AUTOMATIC SYSTEM IS ACTIVATED 112
FIGURE 136: THE ROUGHING LINE LAYOUT DURING THE OPERATION 113
FIGURE 137: THE LAYOUT SHOWS AN ERROR BECAUSE THE BILLET IS STUCK ON THE LINE 113
FIGURE 138: STATISTICS PAGE 114
FIGURE 139: STATISTICS PAGE DURING OPERATION 115
FIGURE 140: STATISTICS PAGE DURING OPERATION 115
FIGURE 141: COMPARISON BETWEEN MANUAL AND AUTOMATIC SYSTEM 117

VIII
TABLE 1: TEMP CONTROLLERS IN FURNACE 7
TABLE 2: CONTROL PANEL OF THE FURNACE 7
TABLE 3: LEFT CONTROL PANEL OF THE STAND 7
TABLE 4: RIGHT CONTROL PANEL OF THE STAND 7
TABLE 5: NUMBER OF INPUTS AND OUTPUTS 9
TABLE 6: TIME ANALYSIS EXTRACTED FROM TREND 14
TABLE 7: TIME ANALYSIS OF THE ROUGHING PROCESS 16
TABLE 8: TIME ANALYSIS OF THE RUFFING PROCESS CONT. 16
TABLE 9: POSITION INFO FOR EACH PARTY 19
TABLE 10: STEPS OF THE PROJECT 20
TABLE 11: PROXIMITY SENSOR FEATURES 22
TABLE 12: PHOTODETECTOR DANIELI FEATURES 24
TABLE 13: COMMUNICATION BOX FEATURES 26
TABLE 14: SENSING HEAD FEATURES 27
TABLE 15: SPRING DESIGN SPECIFICATIONS 66
TABLE 16: INPUTS AND OUTPUTS OF THE AUTOMATED SYSTEM 92
TABLE 17: MOTORS TIME INTERVALS FOR THE MANUAL SYSTEM 116
TABLE 18: MOTORS TIME INTERVALS FOR THE AUTOMATIC SYSTEM 116

IX
 This report contains the details of an upgrading project for a roughing process in a
production line, found in a rolling mill that produces steel rebars. The project takes place in “EL
MARAKBY STEEL (MKS)” factory by a group of four undergraduate students in Cairo
University Faculty of Engineering and supported by the aid of SIEMENS with their vast
experience in industrial automation. The main problem is the unstable efficiency and cycle time
of the process, due to the difference workers’ capabilities. Moreover, there are significant energy
and time losses in the process. The main objective is to enhance the production line performance
through reducing the losses in energy and time in the roughing process and replacing the human
work -done by technicians- by an optimized automated system. This is achieved through a number
of steps which are covered in this report, from studying the process, to generating ideas for
enhancement, passing by the design and selection processes for needed equipment, and reaching
the program that is used to transform the process from manual to automatic, taking into
consideration all possible situations. At the end of the project, an implementation is carried out in
the factory, showing results of the automated process. Finally, comparing old and new results -
before and after automation-, the system has become smoother and easier to control, the
productivity has become stable, and the number of needed control workers has decreased, as the
role of the worker has been limited to observation and only takes action in case of technical errors.
Due to the given results, the factory plans to change the current system to an automated one with
some further tuning.

X
 The world is currently witnessing a fourth industrial revolution, directing all the forces and
efforts towards fully automated industries, which also applies to steel industry, being one of the
pillars of the manufacturing industries. One of the ever-developing factories in steel industry in
Egypt is “EL MARAKBY STEEL” (MKS) group, which started production in 2007, and still
improving and growing till today, owning a number of production facilities mainly focused on
different steel products.

MKS rolling mill is one of the mentioned facilities, producing steel rebars with various
specifications. The roughing process is one of the crucial operations in the production of the steel
rebars, carried out on a three-high rolling stand, as the billet enters the with an initial length of 4
meters and a square cross-section, undergoing 5 rolling hits, and exists with a length exceeding
17 meters and an oval cross-section with much less thickness. This specific operation, unlike the
proceeding ones, is controlled manually by a number of workers, while the rest of the process is
automated. Due to the difference of the workers’ limited capabilities, the operation has an
inconstant and low efficiency. Moreover, there is a noticeable waste in both time and energy
throughout the operation.

The main objective of this project is to either reduce or totally eliminate the previously
mentioned problem, changing the roughing process from a manual operation with considerable
waste, to an automated system with minimal waste closer to ideal conditions. Thus, maintaining a
stable production rate for each given product, sustaining constant working times for all equipment
present in the process, creating further opportunities for development and enhancement, and
making it much easier to study and follow up the process with all its overlapping parameters.

The project undergoes a set of steps to reach its goals, starting with a full study of the
production line, emphasizing on the roughing process, focusing on time studies to learn about the
largest waste present. Following that is a selection process for the equipment that is needed to be
added, whether to reach a fully automated process, or to minimize the waste as much as possible.
After the selection of needed materials, a program is developed to control the process, keeping in
mind all the possible outcomes from ideal conditions to technical errors. The PLC needed for the
program, along with some other components, are loaned from SIEMENS for educational purposes.

Until the previous step, it is all theoretical and no genuine improvement is noticed, which
is why a physical implementation is needed to test the result of the new system. To achieve that,
and with the help of MKS engineers, an electric panel is designed specially to test the project,
carrying the PLC, a set of electric components and modules, and all the required wiring. Finally,
the new results are compared to the initial situation to measure the benefits and show how effective
the modified automated system is.

Page | 1
CHAPTER ONE
 El MARAKBY has been associated with the steel trade for many years, as El MARAKBY
Trading has begun before more than 50 years to distribute steel in various Egypt governorates. It
has shown its ability to identify customers' needs then supply all needs within a suitable supply
period, competitive prices, and methods of sale and thus encouraged many sectors to deal with it.
In 2006, MKS, For Metallic Industries has been established on an area of 60,000 square
meters in 6th of October City with a production capacity of 250,000 tons of various rebars per
year. Actually, it has started to work and produce rebars in 2007.
MKS, For Metallic Industries, produces rebars with diameters from 10mm to 32mm with a
standard length of 12m. It obtained 3 ISO certificates which are ISO 9001, ISO 14001, and OHSAS
18001.
In 2016, El MARAKBY for Steel Billet has established with an annual production capacity
of 350,000 tons. It includes raw material handling system, a 45-ton electric arc furnace, a ladle
furnace with a transformer rating of 8 MVA + 20 percent, and a three-strand billet caster supplied
by SMS group. Billet size is 13cm x 13cm with length 12m.
El MARAKBY for Steel Billet has improved the quality of produced rebars because it could
control all the processes thus produce needed requirements then produce rebars according to
international standards.
Also, El MARAKBY has another sector "6 of October for Steel Marketing" produces steel
structure with a capacity of more than 2000 ton per year through advanced technology. As MKS
gained experience while fabricating the previous plants, because of that now it can provide design,
fabricating spare parts, and perform their maintenance.
El MARAKBY develops itself continuously so when Egypt showed its 2030 view which
interests in the investment of structure and infrastructure, El MARAKBY has decided to increase
the production capacity of rebars. Consequentially, it started to build a new mill with more modern
technology on a larger area at the end of 2017. At the end of the year 2020, the new plant finished
commissioning and went into production.
MKS new mill facility produces rebars with diameters from 10mm to 32mm and wire rod
in shape of coils with diameters from 5.5mm to 12mm.it has designed by SMS Group with the
latest technology and technical concepts.
The new mill facility has many advantages such as higher productivity, less energy
consumption, and zero waste of water.
MKS Steel always interests in product quality, so it finalized a central laboratory equipped
with German testing machines which ensure the highest quality control levels.

Page | 3
 Chapter One: Project Introduction

Figure 1: Stand Front View

Figure 2: Stand Side View

A high rolling mill stand consists of three horizontal rollers of 500 mm diameter separated
vertically from each other by 0.5 meter, they are responsible for the rolling process which is
conducted in five stages through five paths. For each stage there is several groves, one working
and the rest standby until wear of the working grove.
• For stages 1,2,3,4 there are two groves per stage.
• For stage 5 there are four groves.

The lines are separated as follows:

• lines before stand (lines 0,1,3,5)
• lines after stand (lines 2,4,6)

Note that line 5 has two working conditions depending on which grove is used:
• derived by motors with line 1,3
• derived by separate motors.

Page | 4
 Chapter One: Project Introduction

(Line 0) is the line that moves the billet out from the furnace directly, and is separated into two
sections:
1. The first section has 5 motors, each motor drives one roller through a mechanical coupling.
2. The second sector has 2 motors [both sections are continuously running in this manual
control] One
Motor • Drives 3 Rolleres
One
Motor
• Drives 5 Rollers

Without any • 2 Free Rollers

Motors

(Lines 1, 3, 5) are the lines that deliver the billet to strokes 1, 3, 5, and it consists of 6 motors.
Two
• Drive 4 Rolleres Motors

Four
• Drive 4 Rollers Motors

Without any
• 3 Free Rollers Motors

(Line 5) is the line that delivers the billet to stroke 5 when the line 5 is separated, and it consists
of 3 motors.
One
Motor • Drives 4 Rolleres

Two
Motors • Drive 3 Rollers

(Lines 2, 4) are the lines that deliver the billet to strokes 2, 4, and it consists of 5 motors.
One
• Drives 4 Rolleres Motor
Four
• Drive 3 Rollers Motors

Without any
• 2 Free Rollers Motors

Note that: The mechanism of how the electric motors drive the rollers is a belt drive.

Page | 5
 Chapter One: Project Introduction

(Line 6) is the line that delivers the billet to the rest of the production line, it consists of
3 motors
One
Motor • Drives 5 Rolleres
Two
Motors
• Drive 3 Rollers

Without any • 3 Free Rollers

Motors

Figure 3: Before Stand Line Definition Figure 4: After Stand Line Definition

If any problem happens in the rest of the production line or during maintenance while there is billet
is being rolled in the first stand, and it cools down to a temperature that makes it unsuitable for
rolling, it should be removed, which happens as follows:

• If it is on line (0) or line (1) it gets back to the beginning of line 0 and be tipped over by
the tipper mechanism.
• If it is anywhere on lines 2,3,4,5 it is removed by a crane or a forklift.

Figure 5: Top View Illustration of The Stand, Furnace and Lines

Page | 6
 Chapter One: Project Introduction

Figure 6: Control Panel of The Furnace

Figure 7: Control Panel of Temp Controllers in Furnace
Table 2: Control Panel of The Furnace
1 Switch of oil pump for the pusher carriage Table 1: Temp Controllers in Furnace
2 Switch for back door of the furnace 1 Controller one for the heating zone
3 Switch for front door of the furnace 2 Controller one for the socking zone
4 Joystick control for pushers of feeding the furnace
5 Joystick control for the pusher carriage
6 Joystick control for the pusher
7 Alarm of sensor in furnace to control the feeding

Figure 9: Right Control Panel of The Stand

Figure 8: Left Control Panel of The Stand Table 4: Right Control Panel of The Stand
Table 3: Left Control Panel of The Stand 1 Joystick control for motors of line 2,4
1 Joystick control for motors of line 1,3,5 2 Switch alternative to joystick 1
2 Joystick control for motors of line 5 3 Switch control line 6 (line after the stand)
3 Two start buttons of oil pumps of the stand 4 Two stop buttons of water pumps of the stand
4 Two stop buttons of oil pumps of the stand 5 Two start buttons of water pumps of the stand
5 Switch control for motors of line 0 (after 6 Alarm of the water pumps
furnace) 7 Siren alarm for the entire line
6 Button control of the tipper mechanism after 8 Siren alarm for the furnace
the furnace 9 Button switch ON the power to the stand
7 Switch alternative to joystick 1 10 Button switch OFF the power to the stand
8 The communication box of temp sensor 2 on 11 Two buttons reset the power for the electric motor that
the line power the stand

Page | 7
 Chapter One: Project Introduction

Figure 12: The Whole Electric Panel of Power Figure 11: High Torque Motors Contactors
Source for Motors

Figure 10: The Used Relays

Figure 13: The Used Inverters

Page | 8
 Chapter One: Project Introduction

Figure 14: Panel of The Furnace Motors

Figure 15: Line 6 Contactors

As description for the system that will be controlled as for

the electric system there are two types of approaches:
• The use of inverter
• The use of contactors
The use of inverters is for the motors that continuously
change their direction of rotation, which is achieved by
relays.
The use of contactors is for the motors that rarely change
their direction.

The panel starts with a main circuit breaker for all motors
that get the power supply as its input, then a smaller circuit
breaker for each motor, then wired to the relays, then lastly
to the inverter to take the decision.

Table 5: Number of Inputs and Outputs

Inputs Outputs
3 analog inputs 25 outputs for
Figure 16: High Torque Motors Circuit Breakers
15 digital inputs for sensors motors
15 digital inputs for manual control

Page | 9
CHAPTER TWO
 The MKS facility layout that contains the rolling mill production line is considered a medium-
sized steel rolling facility. And since it is limited by its size, it can’t fit a series of the single-stage
mill stands required to reshape the 13cm x 13cm billet to the required rebar product diameters,
which vary from 10mm to 32mm. To overcome this problem, a multiple-stage stand is placed at
the start of the production line to reduce the cross-section of the billet at the same place, from
169𝑐𝑚2 to 38𝑐𝑚2 via five rolling hits.

As it is known in the rolling mill production process, the product usually moves in one
direction, passing from one rolling stand to another. Thus, the process has no idle time since the
product is almost always in contact with the rollers of one of the stands. This means that placing
such a multiple stage stand changes the process property, making the product change its direction
for each time it goes through milling hit, which consequently creates idle time that is consumed in
deceleration, direction change, and acceleration again of the billet.

The conventional rolling mill, because of the unilateral product direction, is easy to control
and automate, so changing the product direction makes the control process more complex, which
is why most of the facilities having multiple stage stand controls the process manually, with an
operator that controls actuators by giving them direct orders.

Moreover, the existence of human interference creates several problems:

1. Limitations of the control as the human capabilities are limited.

2. Reduction of the process efficiency as the operator can’t maintain the optimum operating
conditions at all times.
3. Variation of the process and productivity for the same operator
4. The need for more than one operator to cover all the working hours, which creates a
variation of productivity between working shifts.

As mentioned previously, there is idle time created and this reduces the process efficiency
significantly, thus making this sector of the production line is the bottleneck of the process

Page | 11
 Chapter Two: Project Study

The main aim of our work is to increase the efficiency of the production line as much possible
as can so two approaches are taken to achieve this aim. First, replacing the human operator
controlling the actuators by fully automated system which would give a more control capabilities
of the process, also making the productivity constant and controllable with the biggest benefit of
working on the optimum parameters all the time which give the capability to increase the
productivity in the future.

Second, decreasing the idle time taken between every two rolling hits by any means, as well
as reducing the energy losses as much as possible. So, by the previous two approaches, the overall
productivity of this sector concretely increases making the overall line productivity increase or the
bottleneck change to another sector.

Page | 12
 Chapter Two: Project Study
`

Figure 17: Layout before Automation Page | 13

 Chapter Two: Project Study

Here, we took a trend of the ampere of the electric motor that drives the stand versus time for
knowing that the ampere hikes when there is load (during rolling) and each rolling strike has
different load so each one of them can be recognized, the approach was taken that we had a picture
then made tracing for it then the data is generated to excel to draw the graph that can be analyzed
for data.
The bandwidth of the hiked ampere considered as the rolling strike and the bandwidth between
hikes considered as the idle time (defined as line time in the following table), the delay is the time
taken between the billet to take its last rolling strike and the following billet to take its first rolling
strike. Lastly, the billet period is the time taken from getting out from furnace till going through
the twister that placed before the second stand.

➢ All this data is averaged from 7 trend graphs.

Table 6: Time Analysis Extracted from Trend

Billet
Comp. 1st hit line 2 2nd hit line 3 3rd hit line 4 4th hit line 5 5th hit delay period
max 2.5 6 3.5 4.5 3.5 5 3.5 6 5.5 8.5 62.75
min 2 5 3 3.5 2.5 4 3.25 5 4.5 0.5 61.25
aveg. 2.10 5.67 3.17 4.08 3.06 4.5 3.44 5.72 4.96 3.69 61.94
s.d 0.21 0.35 0.25 0.43 0.30 0.5 0.11 0.36 0.37 2.62 0.53

Figure 18: The Trend of Stand Motor

Page | 14
 Chapter Two: Project Study

Figure 20: Tracing of The Graph

Figure 19: The Generated Graph from Excel

Page | 15
 Chapter Two: Project Study

Basically, what we did here was that we broke down the process into sections and, using a
stopwatch, we took times of each section 10 times, then we analyzed them.
Here line0 stands for the time from furnace to line1, line6 is the time from 5th hit to the
twister, each line is sectioned into two subsections (a & b) as follows:
(a) stands for the time taken by the billet from exiting the rougher till the end of the line.
(b) stands for the time taken by the billet on the line from stop till it reaches the rougher.
Billet period T is the same as the normal billet period, but it was not calculated by summation all
the previous data, but it was simply taken by a stopwatch.

Table 7: Time Analysis of The Roughing Process

Comp. line 0 line 1 1st hit Idle 2-a Idle 2-b line 2 2nd hit Idle 3-a Idle 3-b line 3 3rd hit
max 15.38 6.22 2.3 3.79 4.54 7.31 2.53 2.92 2.86 5.3 2.92
min 14.2 5.6 1.65 2.22 2.39 5.97 1.78 2.28 1.8 4.52 2.08
Avg. 14.82 5.90 1.96 2.80 3.86 6.66 2.25 2.54 2.36 4.90 2.54
s.d 0.37 0.20 0.16 0.49 0.59 0.41 0.19 0.22 0.42 0.34 0.20

Table 8: Time Analysis of The Ruffing Process Cont.

Billet Billet
Comp. Idle 4-a Idle 4-b line 4 4th hit Idle 5-a Idle 5-b line 5 5th hit line 6 period period T
max 2.45 2.88 5.07 3.58 2.21 13.91 15.46 4.56 4.83 71.38 83.68
min 1.83 1.82 4.1 2.84 1.55 1.36 3.07 4.05 4.23 59.05 61.37
Avg. 2.16 2.34 4.50 3.08 1.88 8.06 9.94 4.35 4.53 65.61 71.31
s.d 0.19 0.30 0.30 0.18 0.28 4.76 4.68 0.14 0.15 4.59 7.67

Comparing the trend analysis and time analysis we observe that there are only slight differences
in the average readings and that was expected for four reasons:

• Because the 7 trends that present the 7 billets are different from 10 billet readings of the
time analysis.
• It’s hard on the trend graph to know exactly the start and end points of each rolling strike
and because of that the 2nd hit average in the trend analysis took a longer time than the 3rd
hit which is practically impossible.
• The ampere trend has a big response time for taking the readings which could cause a shift
between the recorded time and the actual time.
• Because of the human factor interferes, so each billet in the trend or the time analysis has
a slight difference in timing, and this is the aim of our project: to remove this factor.

Page | 16
 Chapter Two: Project Study

Before searching for solutions for the given problem and trying to reach the project’s
objective, a thorough study must be conducted. This means gaining as much data as possible about
the rolling mill that needs to be upgraded. For this purpose, many visits are made to MKS to collect
important data, including the facility layout, the machines and tools used, the time analysis for
processes carried out in the factory, the production capacity and other useful data.

The project’s objective is to improve the production line’s bottleneck efficiency, by

designing an automated system for the rougher and upgrading the current system, so firstly all the
needs for the automated system must be selected. Generally, a PLC unit, a new electric panel for
the new system, and a program to implement all orders are needed. Also, the worker’s observation
must be replaced with some detectors, these detector’s types, number, and their places must be
selected carefully. Two main types of detectors are needed, a temperature sensor, and another one
to detect billet’s position. The temperature sensor is needed to check the billet’s temperature and
make sure that the billet has the suitable temperature to go into the rolling mill to protect the rollers
from excessive forces, thus protecting the driving motor from overloading. The other sensor is
needed to detect where the billet is. For temperature sensors, two sensors are needed, and they
already exist on the production line. One of them is positioned after the furnace, and the other one
is before the rougher. For other sensors, it is important to decrease the cost and periodic
maintenance as possible while increasing the system’s reliability, and at the same time use an
efficient way to detect billet’s position accurately, search should be done to select the appropriate
type that serves all these aspects.

Based on that, all the needs are in the following table:

Automated System Requirements

PLC unit
New electric panel
Automated system program
Detectors:
1. Temperature Sensors.
2. Position Detectors.

Secondly, all needs for system upgrade should be selected. The main requirement to
upgrade the system is to replace the current stopper in the line 2 end with an elastic element to
reduce energy losses, thus reduce the motors’ loads that were used to break the billet’s motion. So,
design for the elastic element that conserves this energy must be done, as well as the required
installation body and chassis.

Page | 17
 Chapter Two: Project Study

After determining the main needs to start the project, there are different approaches found
which could all be used to obtain these needs. Each of these approaches has several benefits and -
of course- disadvantages that hindered their use. For example, finding the most suitable detector
for the given conditions is exceedingly difficult, since there are various techniques used in industry
for this specific reason. Thus, a research is carried out to filter the matching approaches and choose
the optimum ones.

For the detection of the billet, three approaches were found to be applicable, which are:
electric sensors, electromechanical devices (another type of sensors such as bearing encoders), or
a mechanical detecting mechanism designed and built specifically for this purpose. And to select
the most fitting approach, it was decided to take a step in all three of them in parallel and see which
one harvests the best results.

Starting by the most available, electric sensors are commonly used in all industries, replacing
the role of the observer, and giving instant feedbacks, making it easier to monitor and control any
system. However, there is several sensors that can be used, varying their method of operation and
their specifications. The following are the main 4 types of both the electric and electromechanical
sensors that can be used:

1. Proximity Sensors.
2. Infrared photoelectric Sensor.
3. Temperature Sensors
4. Electromechanical Sensors.

On the other hand, designing a mechanism solely for detecting the billet position and
motion is a completely different approach, which needed a specific criterion. The main objective
of this approach is to design a mechanism that gives a feedback when the billet passes from a
certain point, sensing its direction of motion as well, without hindering its motion. The motion of
the mechanism could be translated into an electric signal as a feedback by different techniques,
either by stimulating another sensor, or by adding a mechanical switch. Moreover, the weight of
the mechanism must be added into consideration, not only to be easily installed on the line, but
also to have a low manufacturing price. All these factors added together are supposed to be met
when designing the mechanism.

There are also other variant approaches taken in different sections of the project, like designing
a mechanism to store the energy of the moving billet instead of stopping it completely and losing
all its kinetic energy. All these approaches are to be discussed in the following chapter.

Page | 18
 Chapter Two: Project Study

Table 9: Position Info for Each Party

Party Name Position
El MARAKBY Eng. Mostafa Rashad Rolling Mill Plant Manager at El MARAKBY Steel
steel Eng. Ramadan El-Sherbiny Chief Engineer of the Electric Team
Eng. Mostafa Abdel-Mohsen Automation and Control Engineer
Siemens Eng. Sherif El-Naggar Head of Customer Service & Training - Digital
Industries Siemens
Eng. Abdelrahman Maged Field Services Engineer at Siemens
Cairo university Dr. Antoine Dimitri Assistant Professor at
Mechanical Design and Production department

• Siemens

❖ Responsible for supporting us with all technical sessions and information considering
PLC controlling as software and programming, and hardware handling like wiring.
❖ Supporting us with the PLC unit (SIMATIC S7-1200) and all the extension modules that
cover all our needed inputs and outputs, as well as the HMI monitor.

• El MARAKBY Steel

❖ The material they will support us are all needed sensors, executing a
new electric panel, and physical wiring.

• Our team

Our responsibility is divided into two categories:

❖ Mechanical

➢ Simulation of the process as a whole, such as doing analysis of the old process and
trying to reach the optimum state to increase the productivity and making it steady.
➢ Deciding how the sensors and all the system needed component to be integrated into
the existing production line.
➢ Replacing the existing stopper by a spring mechanism to get advantage of the lost
kinetic energy of billet getting out of the rolling stand.

Page | 19
 Chapter Two: Project Study

❖ Electric

➢ Doing logic flow chart.

➢ Programming.
➢ Testing for the logic and program.
➢ Deployment of the system on the factory and test the result.

Table 10: Steps of The Project

First Semester
Studying and analyzing the facility and the process
Drawing a facility layout
Creating a simulation of the process
Determining the points to be upgraded (Planning)
Designing the detecting mechanical mechanisms
Building simulations of the mechanisms (ADAMS/SolidWorks)
Researching for alternatives (sensors/encoders)
Designing a new stopper mechanism (spring calculations)
Constructing a preliminary logic flow
Simulating the stopper mechanism (ADAMS/SolidWorks)
Mid-Year Vacation
Updating the project’s timeline (new Gantt chart)
Documenting any unwritten work
Re-checking calculations (using Shigley)
Choosing the optimum alternative between sensors and mechanisms (sensors)
Drawing the program’s flowchart
Drawing the final layout
Second Semester
Preparing for midyear presentation and presenting
Building preliminary PLC programs
Choosing the optimum program build
Programming the PLC
Testing the program
Implementing the automatic system
Comparing between the manual and automatic process

Note: there are parallel and series tasks.

Page | 20
 Chapter Two: Project Study

There are 5 types of proximity sensors: (Inductive – Capacitive – Ultrasonic – IR – optical

detector)

• As for inductive and capacitive sensors, the difference is the type of metal they detect
inductive sensor for inductive metals and capacitive for non-inductive metals, because their
working principle is the magnetic field.
• Both sensors' temperature limit is 250°C max and they only detect in distance 10 mm to 15
mm far and for that, they are not suitable for our application because they cannot be placed
that near.
• As for ultrasonic it also cannot be used as it works with sonic waves that have to be placed
so near to the detected object and cannot withstand any high temp.
• IR (infrared) cannot be used as the infra-red light emitted from the red-hot metal will
interfere with the sensor infra-red rays.
• Photocell is the type used in the steel industry in various places of the lines. Its working
principle is like the temperature pyrometer, it senses the infra-red rays emitted from the
metal but there are two mechanisms of working:
❖ Thermal detectors respond to the heat energy delivered by light.
❖ Photon detectors that respond to the infra-red light directly.

Figure 21: Effect of Wavelength on Both Photon and Thermal Detectors

Page | 21
 Chapter Two: Project Study
1.1 Proximity Sensor (IG120 – IW100)

Principle of Work

It is an inductive proximity sensor that can detect

metals only, so it’s not affected by the presence of oil,
water, or dust as long as those materials do not contain any
metallic particles.

Table 11: Proximity Sensor Features

Distance of detection Up to 120 mm
Detection field range From 200 mm up to 1200 mm Figure 22: Proximity Sensor
to suit the roller bed width
Ambient temp limit 80 °C

Figure 23: Proximity Sensor Specs

Figure 24: Connection and Wiring

Figure 25: Dimensions

Page | 22
 Chapter Two: Project Study
The material temperature during hot rolling is between 650 and 1250°C, but as previously
mentioned the ambient temperature limit for the sensor is 70°C, so because of the impact of heat
emission on the sensors we are obliged to place the sensor as far from the targeted object as
possible, and this will cause a problem for our project, or solving the question of how this can be
placed and still does its required mission. It’s only to mention there are chemical resistant glass
fibers are suitable and can handle temperatures up to 250 °C, this could be used to limit the distance
positioned.

Also keep in mind that the high temperature of the hot metal is only temporary so this makes
the temperature that the sensor exposed to hikes for short period then it cools down so it might
work in such an environment, but we can’t take this risk.

Page | 23
 Chapter Two: Project Study

There is an already installed photocell sensor on the

line that can be used, and it suits the desired function.

Table 12: Photodetector DANIELI Features

Type Photon detector
Ambient temp limit 70°C
Temp of the object to be >650°C
detected
Response time ON .2 ms
OFF .3 ms
Distance of detection 500 to 2000mm
Detectable spectrum 850 to 1700nm
Weight 1.7 kg
Dimensions 266 x 180 x 64 mm
Range of the observation field vertical: 12°
horizontal: 3°
Casing material pressure-cast Figure 26: Infrared Photodetector DANIELI
aluminum

Principle of Work

The ID2202 uses an IR sensor to measure the quantity of infrared radiation that is present in its
field of view.
A digital output is activated in the presence of hot material, or when the output signal of the sensor
IR exceeds a threshold value, which can be set by a
potentiometer.
A second digital output provides an indication of the
reliability of the detection, signaling anomalies in its
functioning or excessive closeness to the threshold of
detection, and therefore a possible error.
A digital input allows you to select the HMD
sensitivity, so as to ensure reliable detection of both
‘cold’ (T > 450°C), and ‘hot’ (T > 650°C) materials.

*It should be considered how far the sensor is placed

to know the dimension of product it can detect (the
Figure 27: Diversion of Detection Range
range spot it can detect)

Page | 24
 Chapter Two: Project Study

3.1 The Concept of The Sensor

All surfaces emit infrared radiation. The intensity of this infrared radiation changes
according to the temperature of the object. Depending on the material and surface properties, the
emitted radiation lies in a wavelength spectrum of approximately 1 to 20 µm. The intensity of the
infrared radiation (heat radiation) is dependent on the material. For many substances, this material-
dependent constant is known. This constant is referred to as the “emissivity value”. Infrared
thermometers are optical-electronic sensors. These sensors are sensitive to the emitted radiation.
Infrared thermometers are made up of a lens, a spectral filter, a sensor, and an electronic signal
processing unit. The task of the spectral filter is to select the wavelength spectrum of interest. The
sensor converts the infrared radiation into an electrical signal. The signal processing electronics
analyze the electrical signal and convert it into a temperature measurement. As the intensity of the
emitted infrared radiation is dependent on the material, the required emissivity can be selected on
the sensor. The biggest advantage of the infrared thermometer is its ability to measure temperature
without touching an object. Consequently, surface temperatures of moving or hard to reach objects
can easily be measured.

*The temperature sensor is divided into two main components: sensing head and communication
box.

*Some temperature sensors are already installed on the line, so we will not consider buying a
new type of sensors. There are two of them and can be increased up to three.

Page | 25
 Chapter Two: Project Study
3.2 Communication Box

Figure 29: Communication Box

Table 13: Communication Box Features

Price around 200$
Ambient temp limit 65°C
Reading accuracy showing ± 1°C
Temperature Resolution ± 0.1°C (± 0.2°F)1 / 12 bit
Analog type reading output Can support all output types:
0 to 20 mA (active), or 4 to
20 mA (active), or 0 to 5 V,
or 0 to 10 V
Figure 28: Communication Box Specs. Loop Time 4 ms
Weight 370 g
Material die-cast zinc enclosure
Relative Humidity 10% to 95% non-condensing

The box is equipped with three cable feed-through ports – two with IP65 compatible sealing
glands, a third sealing gland comes for boxes with fieldbus communications (RS485, Profibus
etc.). Boxes without fieldbus have a plugged expansion feed-through port instead (M12x1.5
thread).

Figure 30: Communication Box Dimensions

Page | 26
 Chapter Two: Project Study
3.3 Sensing Head

Table 14: Sensing Head Features

Price around 450$
Ambient temp limit 120°C
Reading temp range 250 to 1400°C
Spectral Response 1.6 µm
Optical Resolution 100:1
D:S (distance to spot)
Response Time 10 ms3
Weight 233 g
Accuracy ± (0.5% of reading or
2°C)
whichever is greater
Material Head: Stainless steel
Head Cable: PUR
(Polyurethane)
Relative Humidity 10% to 95% non-
Figure 31: Sensing Head condensing

Figure 32: Sensing Head Dimensions

Figure 33: Assembly of Communication Box and Sensing Head

Figure 34: Different D.S (Distance to Spot) Explanation

Page | 27
 Chapter Two: Project Study

COMPACT AND RELIABLE MOTOR ENCODER TECHNOLOGY

Monitoring the status of rotating components

accurately is essential for many applications. This is
particularly true for AC motors that require encoders to
measure the speed and the direction of rotation continuously.

Figure 35: SKF Bearing Encoder

Designs and Variants

SKF motor encoder units are compact, integrated units consisting of:

• an SKF Explorer deep groove ball bearing in the 62 series with a snap ring groove in the
outer ring and an RS1 contact seal (Single row deep groove ball bearings)
• an impulse ring.
• a sensor body.
• a connecting cable
The impulse ring, which attaches to the inner ring of the bearing, is a composite magnetized ring
that contains between 32 and 80 north and south poles. The number of poles depends on the size
of the bearing. The sensor body, which is attached to the outer ring, protects the patented SKF Hall
effect cell. The multi-wire connecting cable extends in the radial direction.

The bearing is protected by a contact seal on one side. On the opposite side of the bearing, the
impulse ring and sensor body create an effective labyrinth seal to keep lubricant in and solid
contaminants out of the bearing.

Page | 28
 Chapter Two: Project Study
Sensor Technology

SKF motor encoder units use a compact and robust sensor that produces an incremental
encoder signal. The sensor is accurate down to zero revolutions per minute. An integrated active
circuit (requiring an external voltage supply) in the sensor body contains two Hall effect cells
that produce an output signal consisting of two square waves.

The signals can be interpreted by motor controllers in different ways:

• The direction of rotation can be determined from the phase shift when the rising edge of a
signal first appears.
• Low speeds can be determined by measuring the time between two electrical events, such
events being the rising and falling edge on either square wave.
• High speeds can be measured by counting the number of electrical events within a given
time.
The two square waves are 90° out of phase with each other. This phase shift changes sign with
the direction of rotation. The presence of two signals in quadrature enables a processing unit to
multiply the number of angular position increments per revolution. For example, using a standard
SKF sensor bearing with 64 pulses per revolution and a standard electronic interface that can detect
the rising (Low/High) and falling (High/Low) times of each of the two signals, it is possible to
obtain 256 electrical events per revolution, which translates to an angular resolution of 1,4°.

SKF motor encoder units provide accurate and reliable signals for effective motor control and are
100% tested for period accuracy, duty cycle and phase shift during manufacture.

Caple Connections

SKF motor encoder units are available as standard with one of the following:

• a free cable end with an output signal consisting of two square waves, designation suffix
008A.
• an AMP Superseal™ connector (AMP Nos. 282106-1 and 282404-1), designation suffix
108A.

Page | 29
 Chapter Two: Project Study
Temperature Limits

SKF motor encoder units have been tested successfully under various speeds and loads:

• 500 hours at 125 °C (255 °F), with intermittent peaks of up to 10 minutes at 150 °C (300
°F)
• 100 hours at –40 °C (–40 °F)

Bearings Data

Figure 36: Data Available for SKF Bearing Encoder

Mounting

SKF motor encoder units must be handled with care to avoid damaging the bearing, sensor and
connecting cable. Never apply any force on the cable, cable outlet, sensor body or impulse ring.

Page | 30
 Chapter Two: Project Study

Motion and Direction Detection Problem

During the process of updating the roughing

line to be automatically controlled, it becomes in a
need of using sensors. After search, sensors are
found, which technically applicable but not able to
work under extreme conditions like high temperature
and steel dropped slag. There are also applicable
sensors for those conditions but with not economical
pricing.

Figure 37: Proximity Sensor Exposed to High Temperature

So, to solve this problem there is an attempt to use

an economical common proximity sensor, but to get
it out from the extreme conditions and to transmit the
detection motion to it using a metallic mechanism
suitable for these conditions.

Detection Mechanism (First Attempt) Figure 38: Extreme Operation Conditions for Sensors

Page | 31
Figure 39: First Attempt Mechanism
 Chapter Two: Project Study
Illustration

It is a simple spring mechanism which moves vertically by the

weight of the steel billet, this vertical motion is transferred to the
sensing head of the proximity sensor by a rod which maintains its
position as long as the billet forcing the mechanism downwards. The
mechanism position resets by a spring when the billet moves away
from its roller.

General Dimensions

Figure 42: Section of First Mechanism

Figure 40: Front View of First Mechanism

Figure 41: Isometric View of First Mechanism

Page | 32
 Chapter Two: Project Study
Main Components and Fixation

1. A roller on which the billet will roll over and push 1

the mechanism downwards due to difference in
2
height with the line rollers.
2. Two Slotted Brackets which fixed to the line bed
and oblige the mechanism to move vertically without
3
twisting around its axis and maintain a fixed height
for the roller whatever the height of the bed.
5
3. A bracket on which the roller is fixed and two rods 4
with rubber sleeves extracted from it to mate with
7
the slotted brackets. 6
4. A rod which fixed to the bracket for transmitting the
vertical motion to the sensor.
5. A spring to reset the mechanism to its position.
6. Two hooks to force the mechanism downwards during
the maintenance of the line.
7. A hollowed cylinder which is fixed to ground containing Figure 43: First Mechanism Components
a safe housing for sensor and two hook earrings.

Figure 46: Mechanism Spring Element Figure 44: Mechanism Hooks

Figure 45: Mechanism Rubber Sleeves and Sensor Housing
and Slotted Brackets

Page | 33
 Chapter Two: Project Study
Problems

The main and almost only problem of this

mechanism is the high potential of axial force which is
applied by the moving heavy weight steel billet. This
axial force is a problem because it may cause a
destruction to the mechanism. The clearance between the
moving rod and the spring, and between the spring and
the fixed cylinder may cause difficulty in motion when
this force is occurred. Although this axial force is taken
into considerations and prepared the mechanism to bear
it, but it still poses a threat on the mechanism.

Figure 47: Direction of Axial Force Acting on First Mechanism

Page | 34
 Chapter Two: Project Study

The Purpose

As mentioned in first attempt, the only and

annoying problem is the impact axial force applied by
the moving heavy weight steel billet. The more the
detection mechanism resists this force the more it will
be destroyed.

Although the first attempt mechanism was making a

perfect vertical movement by spring assembly but not
good enough to obey this impact axial force. In the
second attempt a detection mechanism is designed to
solve this problem as follows.

Figure 48: Axial Force Illustration

Detection Mechanism (Second Attempt)

Figure 49: Second Mechanism

Page | 35
 Chapter Two: Project Study
Illustration

It is a simple mechanism which is made based

on the pendulum physics taking its motion by the hit of
the weighted moving billet and resets its position by
the bottom weighted body. This mechanism could be
totally assembled with the bottom of beds which
provides more rigidity and could detect the direction of
the moving billet by the Inverted movement of the
pendulum.

General Dimensions Figure 50: Section of Second Mechanism

Figure 51: Front View of Second Mechanism

Figure 52: Isometric View of Second Mechanism

Page | 36
 Chapter Two: Project Study
Main Components and Fixation
1.1
1 2
1. The mechanism chassis which contains:
3
1.1 Four screwed studs to be fixed by four nuts with the bed.
1.2 Bearing houses for cam body shaft.
1.2
1.3 Two houses for proximity sensors.
1.4 A base which a piece of rubber fixed with to resist the
oscillation of the pendulum after being hit by the billet.
2. A cam, which is made by welded metal sheets using its profile
to make the hit of the billet as smooth as possible.
3. A shaft, which is assembled to cam body by a biscuit.
4. A weighted body welded to the cam body making the pendulum 1.3
5 1.4
movement when the cam is hit by the billet.
5. Two pieces of rubber connected to the weighted body and the Figure 53: Second Mechanism Components

chassis base generating the needed fiction.

Figure 54: Rubber Resistance

Figure 55: Bearing Housing and Cam Profile

Page | 37
 Chapter Two: Project Study

Adams Impact Simulation for Second Attempt

The Dynamic Model Before Billet Hit

Figure 56: ADAMS Dynamic Model before Hit

The Dynamic Model During Billet Hit

Figure 57: ADAMS Dynamic Model during

Page | 38
 Chapter Two: Project Study

General Parameters of The Simulation Model

1. Steel billet mass = 531 kg

2. Total mass of the mechanism = 23.8 kg
3. Rotating mass = 15.4 kg
4. Distance between center of mass and center of rotation = 5 cm
5. Permissible working angels 33 to 53 degrees.

Results of The Simulation

• The first graph represents the deformation angle in the torsional spring vs time.

• The second graph represents the torque exerted by in the torsional spring vs time.

Spring Behavior (Angles)

Figure 58: Spring Angles Behavior vs Time

Page | 39
 Chapter Two: Project Study
Spring Behavior (Torques)

Figure 59: Torque Applied to Spring vs Time

Simulation Parameters:

• Friction between the cylinders and billet (friction coefficients between steel and steel dry)
➢ Static coefficient = .6 (worst-case scenario: there is no rolling)
➢ Dynamic coefficient = .48
• Type of hitting: restitution with coefficient =.3 (between hot steel at 900c and steel) [1]
• Type of simulation: dynamic
• Velocity of the billet = 3.5m/s
• Equivalent total torsional stiffness K = 4.5N.m/degree
• Step size: .001second (The least event can be seen in this period)

Results of The Simulation:

1. The maximum angle at impact instant = 51.68 degree and equivalent torque exerted by the
torsional spring = 232.6 N.m
2. The steady angle during the billet passing = 33 degree and equivalent torque exerted by the
torsional spring = 148.6 N.m

Page | 40
 Chapter Two: Project Study
Third method (MITCalc spring design)

❖ The total load was divided by 2 because there will be two torsional spring that support the
torque. (𝐷𝑒𝑠𝑖𝑔𝑛 𝑇𝑜𝑟𝑞𝑢𝑒 = 116 𝑁. 𝑚)

Operating Conditions

Figure 60: Spring Operating Conditions

Material and Working Conditions

Figure 61: Spring Material and Working Conditions

Page | 41
 Chapter Two: Project Study
Results of The Design

Figure 62: MITCalc Results

Summary of Spring Design (Two Torsional Springs)

1. Spring constant K= 2248 N.mm/degree
2. Limit loading 223.3 N.m (factor of safety = 1.9)
3. Mass 5.44kg
4. Dimensions
Outer Diameter = 65.8mm
Inner Diameter = 35.8mm
Wire Diameter = 15mm
Free Length = 367.5mm

Problems
The main problem is that to support this torque the torsional spring should have space for
its free length = 36.7 cm and this is not suitable for our small working area.

Page | 42
Chapter Two: Project Study

Page | 43
Chapter Two: Project Study

Page | 44
CHAPTER THREE
 The purpose of this chapter is to design (select the parameters of) the optimum spring that
would act as a stopper instead of a rigid wall to get the most benefit of the lost kinetic energy.

The main role of the chapter is to show the results of the approaches that have been acquired
through numerous iterations using:

1. Showing the benefit of replacing the rigid wall with the spring, by comparison, the
conditions before and after the spring.
2. Showing the various methods that have been approached to verify each other.

The methods used:

1. Adams impact simulation.

2. SolidWorks motion analysis.
3. MITCalc spring design.
4. MATLAB simulation and SIMSCAPE.

Page | 46
 Chapter Three: Stopper Mechanism

The main purpose of using Adams is to simulate the process happening in real life right now
and getting its effect on the elements and see the alternative behavior after replacing the rigid wall
with spring and take the result from here and go design the spring itself and get its parameters and
dimensions that would support this impact and do the behavior required from it.

➢ The Dynamic Model Before Hitting

Figure 63: ADAMS Dynamic Model before Hitting

➢ The Billet End Position After Hitting the Rigid Wall

Figure 64: Billet Position after Hit the Wall Page | 47

 Chapter Three: Stopper Mechanism

➢ The Billet End Position after Hitting the Spring

Figure 65: Billet Position after Hit the Spring

1. Steel billet mass = 531kg

2. Plate at end of the spring mass = 7kg
3. Available space of the spring = 70cm
4. Stiffness of spring K = 170N/mm (this value is obtained from multiple iterations on
ADAMS software to get the optimum value that gives the best behavior for the return
velocity)
5. Structural damping coefficient c = 396N.s/m (structural damping of any spring can only be
measured experimentally but this value is the suggested value from Adams for stiffness K
=170N/mm)
6. Friction between the cylinders and billet (friction coefficients between steel and steel dry)
Static coefficient =.6 [2] (There is no rolling making worst-case scenario for billet speed as it
Dynamic coefficient =.48 would decrease significantly with time)

Page | 48
 Chapter Three: Stopper Mechanism

The simulation will be done with two values of initial speed 1- 3.5m/s (maximum speed)
2- 2.5m/s (lower speed as it could not reach the maximum speed)

Figure 66: Billet Velocity vs Time

The graph represents the velocity of the billet vs time in the three conditions:

1. Hitting rigid wall.

2. Hitting spring has no damping coefficient.
3. Hitting spring has structural damping coefficient c =396N.s/m).

• Red line represents the behavior impact with the rigid wall.
• Blue line represents the behavior after impact with the spring has no damping coefficient.
• Pink line represents the behavior after impact with the spring has structural damping
coefficient c =396N.s/m.
•
Simulation Parameters

• Type of hitting: restitution with coefficient =.3 (between hot steel at 900c and steel) [1]
• Type of simulation: dynamic
• Initial velocity of the billet = 3.5m/s
• Step size: .001second (the least event can be seen in this period)

Page | 49
 Chapter Three: Stopper Mechanism

Result of the Simulation

1. The velocity of the billet after hitting the rigid wall is V=.95m/s
2. The velocity of the billet after hitting the spring with no damping coefficient is
V=2.91m/s at time =.176sec
3. The velocity of the billet after hitting the spring with damping coefficient c =396N.s/m is
V=2.53m/s at time =.172sec

Figure 67: Billet Velocity vs Time

The graph represents the velocity of the billet vs time in the three conditions:

1. Hitting rigid wall.

2. Hitting spring has no damping coefficient.
3. Hitting spring has structural damping coefficient c =396N.s/m )

• Red line represents the behavior impact with the rigid wall.
• Blue line represents the behavior after impact with the spring has no damping coefficient.
• Pink line represents the behavior after impact with the spring has structural damping
coefficient c =396N.s/m

Page | 50
 Chapter Three: Stopper Mechanism

Simulation Parameters

• Type of hitting: restitution with coefficient =.3

• Type of simulation: dynamic
• Initial velocity of the billet = 2.5m/s
• Step size: .001second (the least event can be seen in this period)
Result of The Simulation

1. The velocity of the billet after hitting the rigid wall is V=.71m/s
2. The velocity of the billet after hitting the spring with no damping coefficient is
V=1.89m/s at time =.176sec
3. The velocity of the billet after hitting the spring with damping coefficient c =396N.s/m is
V=1.74m/s at time =.174sec

• The first graph represents the force exerted by spring vs time.

• The second graph represents the deflection that happens in spring vs time.
Both in two conditions:
1. Hitting spring has no damping coefficient.
2. Hitting spring has structural damping coefficient c =396N.s/m )

• Red line represents the behavior after impact with the spring has no damping coefficient.
• Blue line represents the behavior after impact with the spring has structural damping
coefficient c =396N.s/m

Page | 51
 Chapter Three: Stopper Mechanism

Figure 68: Spring Forces vs Time

Figure 69: Spring Deflection vs Time

Result of the Simulation

1. The maximum force exerted by the spring = 30354N

2. The spring reaches the maximum force at .09sec
3. The maximum deflection happens at the same time and its value =17.85cm
4. The periodic time of the oscillation after impact =.04sec then the frequency=24.4Hz

Page | 52
 Chapter Three: Stopper Mechanism

The main purpose of using SolidWorks is to verify the result obtained from Adams as for a
software algorithm check.

This was done by building the same model on SolidWorks but with no friction applied between
the billet and the cylinders to see the worst-case scenario on the spring.

➢ The Dynamic Model

Figure 70: SOLIDWORKS Dynamic Model

• The first graph represents the force exerted by spring vs time hitting spring has no damping
coefficient.
• The second graph represents the deflection that happens in spring vs time hitting spring has
no damping coefficient.
• The third graph represents the velocity of the billet vs time hitting spring has no damping
coefficient.
• The fourth graph represents the velocity of the billet vs time hitting a rigid wall.

Page | 53
 Chapter Three: Stopper Mechanism

Figure 71: SOLIDWORKS Simulation Results

1. The maximum force exerted by the spring = 33029N

2. The spring reaches the maximum force at .09sec
3. The maximum deflection happens at the same time and its value =19.42cm
4. The periodic time of the oscillation after impact =.04sec then the frequency=24.4Hz
5. The velocity of the billet after hitting the spring with no damping coefficient is V=3.4m/s
6. The velocity of the billet after hitting the rigid wall is V=.945m/s
❖ Note that the only differences in the result are a slight increase got in the maximum force,
deflection, and velocity after impact in the spring condition that because of the absence of
the friction between the billet and the cylinders.

Page | 54
 Chapter Three: Stopper Mechanism

The main purpose of using MITCalc is to design the spring and do multiple iterations in a
short period of time.
The inputs for the software are the applied force we got the deflection and the initial length
(working lengths).
The outputs are the final dimensions of the spring and factor of safety.

Figure 72: Spring Operating Conditions

Figure 73: Spring Material and Working Conditions

Page | 55
 Chapter Three: Stopper Mechanism

Figure 74: MITCalc Spring Design Results

1. Spring constant K=170N/mm

2. Limit loading 44213.63N (factor of safety = 1.45)
3. Mass 61.8Kg
4. Natural spring frequency f = 32.4 Hz > (1.15* oscillation frequency=1.15*24.4=28 Hz)
5. Dimensions
outer diameter =366.64mm Resonance effects occur with compression springs exposed to
fatigue loading. To eliminate these effects, it is necessary to
inner diameter =286.64mm
load the spring at an excitation frequency different from the
wire diameter =40mm characteristic frequency of the spring (by approx. 15%).
free length =500mm
number of active coils =4

Page | 56
 Chapter Three: Stopper Mechanism

As MITCalc doesn’t support the market material and also its output isn’t restricted to any
geometric restriction, so it gives trivial solutions considering the dimensions.

So, we will use the output dimensions from MITCalc as a start point for the actual spring that
will be winded.

Figure 75: Online Calculator Spring Material and Mass Properties

Figure 76: Online Calculator Spring Dimensions

1. Material (Music Wire ASTM A228)

2. Spring constant K=170N/mm
3. Limit loading 31227N (factor of safety = 1.03)
4. Mass 67.4Kg
5. Solid length = 280mm
6. Dimensions
outer diameter =350mm
inner diameter =270mm
wire diameter =40mm
free length =500mm
number of active coils =5
7. Maximum allowed travel distance 183.5mm (margin of safe travel distance =183.5-178.5
= 5mm)

Page | 57
 Chapter Three: Stopper Mechanism

The main purpose of using MATLAB simulation and Simscape is to see the vibration
behavior of the spring during and after impact.

k=170000; m=538; wn=sqrt(k/m); z=.02; c=z*(2*sqrt(k*m)); x0=0; dx0=3.5;

wd=(sqrt(1-z^2)*wn);
t=[0:.01:10];
Y=(exp(-z*wn.*t)).*((x0*cos(wd.*t))+(((dx0+z*wn*x0)/(wd)).*(sin(wd.*t))));
plot(t,Y,'k' , 'LineWidth', 2)
grid on
xlabel('Time (seconds)')
ylabel('Amplitude(deflection in (m))')
title('Total Response')

❖ Note that during impact the mass that vibrate is the summation of plate and billet masses
=7+531 =538kg
m =538kg k =170N/mm V=3.5m/s

First Attempt
c =0N.s/m ζ = 0

Figure 77: Spring Deflection vs Time under c =0N.s/m ζ = 0

Page | 58
 Chapter Three: Stopper Mechanism

Second Attempt

c =1917N.s/m ζ =.1

Figure 78: Spring Deflection vs Time under c =1917N.s/m ζ =.1

Third Attempt
c =396N.s/m ζ =.02

Figure 79: Spring Deflection vs Time under c =396N.s/m ζ =.02 Page | 59

 Chapter Three: Stopper Mechanism

Result of the Simulation

1. From the first attempt the maximum deflection =19.3cm and first peak happens at .1sec
2. From the second attempt the maximum deflection =16.9cm and happens at .09sec
3. From the third attempt the maximum deflection =19cm and happens at .09sec
4. From the third attempt the periodic time =.35sec so the damped frequency =2.85Hz

❖ Note that after impact the mass that vibrate is only the mass of plate = 7kg
m =7kg k =170N/mm V=3.5m/s

First Attempt

c =0N.s/m ζ =0

Figure 80: Spring Deflection vs Time under c =0N.s/m ζ =0

Second Attempt

c =396N.s/m ζ =.1815

Figure 81: Spring Deflection vs Time under c =396N.s/m ζ =.1815

Page | 60
 Chapter Three: Stopper Mechanism

Result of the Simulation

1. From the first attempt the maximum deflection =2.2cm and first peak happens at .01sec
2. From the second attempt the maximum deflection =1.7cm and happens at .009sec
3. From the second attempt the periodic time =.041sec so the damped frequency =24.4Hz

The main purpose of using SIMSCAPE simulation is that it has a more accurate scope manipulator
and has more options.
➢ Circuit Model

Figure 82: SIMSCAPE Model

(All graphs are deflection amplitude vs time)

m =538kg k =170N/mm V=3.5m/s

First Attempt
c =0N.s/m ζ =0

maximum deflection =19.3cm and

first peak happens at .083sec
Figure 83: Spring Deflection vs Time under c =0N.s/m ζ =0
Page | 61
 Chapter Three: Stopper Mechanism

Second Attempt
c =1917N.s/m ζ =.1

maximum deflection =16.7cm and

happens at .083sec

Figure 84: Spring Deflection vs Time under c =1917N.s/m ζ =.1

Third Attempt
c =396N.s/m ζ =.02

maximum deflection =18.8cm and

happens at .083sec

the periodic time =.354sec so the

damped frequency =2.82Hz

Figure 85: Spring Deflection vs Time under c =396N.s/m ζ =.02

Page | 62
 Chapter Three: Stopper Mechanism

(All graphs are deflection amplitude vs time)

m =7kg k =170N/mm V=3.5m/s
First Attempt
c =0N.s/m ζ =0

maximum deflection =2.16cm and

happens at .01sec

Figure 86: Spring Deflection vs Time under c =0N.s/m ζ =0

Second Attempt
c =396N.s/m ζ =.1815

maximum deflection =1.59cm and

happens at .01sec

the periodic time =.0426sec so the

damped frequency =23.42Hz

Figure 87: Spring Deflection vs Time under c =396N.s/m ζ =.1815

Page | 63
 Chapter Three: Stopper Mechanism

m =538kg k =170N/mm V(initial)=3.5m/s c =396N.s/m ζ =.02

❖ Note that maximum velocity happens after the first time getting to the initial position

➢ Deflection Amplitude vs Time

first time getting to the

initial position =.177sec

Figure 88: Spring Deflection vs Time

➢ Velocity vs Time

The maximum velocity

=3.17m/s and happens at
timing =.175sec

Figure 89: Spring Velocity vs Time

Page | 64
 Chapter Three: Stopper Mechanism

In the impact analysis we can consider it is ideal with no losses in friction or losses by
converting energy to sound.
So kinetic energy (of moving mass) = potential energy (of spring)
1 1
mv 2 = kx 2
2 2
m: mass of the billet (500kg)
v: speed of billet (3.5m/s)
k: spring stiffness (170,000N/m)
x: spring deflection (m)
1 1
∗ 500 ∗ 3.52 = 2 ∗ 170,000 ∗ 𝑥 2
2

Then the corresponding deflection of spring x=.19m

G ∗ d4
k=
8 ∗ D3 ∗ na
k: spring stiffness (N/m)
G: shear modulus of material (79,241,245,136 Pa)
d: wire diameter (.04m)
D: mean diameter (.31m)
na : number of active coils (5)
G∗d4 79,241,245,136∗.044
k = 8∗D3 ∗n = = 170,234 N/m
a 8∗.313 ∗5

Page | 65
 Chapter Three: Stopper Mechanism

After all, Adams showed that replacing the rigid wall with a spring will result in the benefit
of saving 2 m/s of the billet velocity and this increase of initial velocity after reversing the direction
will help the motors - accelerate the billet easier and in less time.

SolidWorks simulation and MATLAB simulation of vibration got the same result as Adams in the
amplitudes of the spring deflection and velocity, which proves the validity of Adams’ algorithm
and impact analysis.

Spring design using MITCalc and Calculator got that there is a spring that could withstand the
force exerted on it having the stiffness needed to do the required behavior with dimensions
relatively appropriate to the concerned application also appropriate for winding.

Table 15: Spring Design Specifications

Material Music Wire ASTM A228
Spring constant (K) 170N/mm
Mass 67.4Kg
Dimensions
Outer diameter 350mm
Inner diameter 270mm
Wire diameter 40mm
Free length 500mm
Number of active coils 5

Finally, the simple engineering equations verified the impact analysis software and calculator.

Page | 66
 Chapter Three: Stopper Mechanism

As the operating environment is dealing with product has extremely high elevating temperature
(1100 ℃), this high value of temperature must be taken into consideration. As shown in figure
(34).

Figure 90: Spring Constant vs Temperature

The spring constant value decreases with increase of temperature according to the behavior
illustrated in the previous graph [3]. Although the tested spring in this research paper has a different
spring constant value to our spring, this graph is applicable for a wide range of spring constants.

A temperature gun is used to measure the actual temperature of the existing stopper plate installed
on the line and its value was about 94 ℃ during operation, this value will be the temperature of the
stopper mechanism spring element. According to Figure (34), there is no considerable effect of
temperature on the spring constant starting from 300 ℃.

So, the designed stopper mechanism spring element in this environment conditions will not be
affected.

Page | 67
 Chapter Three: Stopper Mechanism

Figure 91: Mechanism Isometric Views in Neutral Condition

Figure 92: Mechanism Isometric View in Working Condition

Page | 68
 Chapter Three: Stopper Mechanism

1 11
1. Front Plate (Impact Plate)
2. Rear Plate (Fixed Plate)
3. Spring 8 3
4. Spring Cup
5. Longitudinal Rod
10
6. Sleeve
7. Pin
8. Shaft
9
9. Pulley
10. Shockproof Locker
11. Bearing 4
6

Figure 93: Stopper Mechanism Components

Page | 69
 Chapter Three: Stopper Mechanism

It is designed to be fixed with the modified existing end-line

portions of the bed. Corresponding to dimensions, the fixation
should be done not at the same level with the line, that is for making
the billet hit to be at the center of the spring. According to idle times,
the existing plate at end-line two will be replaced by the stopper 6 4 2
mechanism and another one should be placed at the end-line four.

Figure 94: Illustration of Line 2, 4 and 6

The assembly of the stopper mechanism with the modified

end-lines two and four will ensure a perfect hit from the billet to the
center of the acting spring. Applying a rectangular sector cut to the
bed with respect to the mechanism dimensions, taking into
consideration the height made by rollers circumference from the
bed surface will ensure that perfect hit.

Figure 95: Line 2 and 4 after Modification

Besides the rectangular sector cut made
to the bed, a side rectangular sector cut should
be made to the line walls in order to weld a rod
as a support and a tow bar for the mechanism.
This bar is welded at a predetermined height
suitable for the required location for the billet
hit.

Figure 96: Stopper Assembly with the Bed

The mechanism is fixed by welding at its rear

plate to the line bed and the line side walls. A cut is
made to the bed to act as a shoulder for the rear plate
to rest on it. The real plate is welded from its back with
a U shape and from its front face with an L shape for
both sides.

Figure 97: Fixed Plate Fixation with the Bed

Page | 70
 Chapter Three: Stopper Mechanism

The Stopper Mechanism front plate that will

face the billet and take the hit should be free related to
the bed. Four long rods are welded to the plate passing
through sleeves fitted to the rear plate. Premade -non
through all- holes are cut into the plate to work as guide
for the rods.

Those four long rods are prepared with radial

holes to be fitted with four pins. The pins will be
responsible for preloading the spring and system
coherence after every billet hit. The front plate is
equipped with a loading handle to be loaded from while
assembling.
Figure 98: Impact Plate Assembly with the Stopper

Two Spring cups are welded in reverse to the

front and rear plates respectively, those cups are
responsible for holding the spring position to the center
of the mechanism. The cups are supplied with stoppers
to prevent the spring from rotating around itself.
Premade -non-through all- holes are cut into the plates
to work as a guide for the cups.
Figure 99: Spring Cups Fixation with the Plates

A cross shaft is made for the pulleys rolling on

the line wall rods, this shaft is designed to be fixed by
welding with the upper long rods. Two radial holes are
made to the shaft to enable the upper rods to pass
through, then to be welded together at a pre-
determined position. The chassis of the stopper
mechanism weights 84 kilo grams without the spring
element.

Figure 100: The Pulleys and their Supporting Shaft

Page | 71
Chapter Three: Stopper Mechanism

Page | 72
Chapter Three: Stopper Mechanism

Page | 73
Chapter Three: Stopper Mechanism

Page | 74
Chapter Three: Stopper Mechanism

Page | 75
Chapter Three: Stopper Mechanism

Page | 76
Chapter Three: Stopper Mechanism

Page | 77
Chapter Three: Stopper Mechanism

Page | 78
Chapter Three: Stopper Mechanism

Page | 79
Chapter Three: Stopper Mechanism

Page | 80
Chapter Three: Stopper Mechanism

Page | 81
Chapter Three: Stopper Mechanism

Page | 82
Chapter Three: Stopper Mechanism

Page | 83
 Chapter Three: Stopper Mechanism

Earlier at this chapter, we have made an impact simulation on the spring element in this
stopper mechanism resulting in selecting a suitable spring type and suitable dimension for the task.

At this step, simulations made to focus on the supporting chassis of the spring element. Applying
both static and dynamic simulations intending to make this mechanism acceptable and reliable as
well. The effect of temperature is neglected in those simulations. A temperature gun is used to
measure the actual temperature of the existing stopper plate installed on the line and its value was
about 94 ℃ during operation which does not affect the material properties.

1. Impact Plate Simulation

❖ Simulation Setup

This simulation is made by SOLIDWORKS

simulation module. To set the end time for the
dynamic simulation in SOLIDWORKS, the
impact time interval resulting from the impact 0.002825-0.002775 = .00005
analysis made previously by ADAMS is used.

Figure 101: ADAMS Impact Force vs Time

Figure 102: Properties of Nonlinear-Dynamic Simulation Page | 84

 Chapter Three: Stopper Mechanism

❖ Result

Figure 103: Stresses Applied on the Impact Plate

According to shown figures, the

maximum stress on the impact plate equals to
477 MPa which is more than the yield strength
of AISI 1020 -Plate’s Material- 351 MPa, but
this high stress value is concentrated at a very
tiny region.

As illustrated in Figure (106), those are the only

tiny regions on where this high value of stress is
exerted, which is more than the value plate
material yield strength.

Figure 104: Maximum Stress Regions on the Impact Plate

Page | 85
 Chapter Three: Stopper Mechanism

2. Pins Simulation
❖ Simulation Setup

This dynamic simulation is so critical for the stopper

mechanism to be safe, that is because of the importance of
the component itself -stopper pin-. As illustrated
previously, it is responsible for preloading the system
spring and maintaining the whole system in a specific
geometry preventing it from failing.

This time, the four pins are dealing with the impact
bouncing back while the billet leaves the impact plate. This
simulation is made by SOLIDWORKS simulation module.
To set the end time for the dynamic simulation in
SOLIDWORKS, the impact time interval resulting from
the impact analysis made previously by ADAMS is used.

Figure 105: Properties of Nonlinear-Dynamic Simulation

0.1803-0.1802 = .0001

Figure 106: ADMAS Impact Velocity vs Time

Figure 107: SOLIDWORKS Simulation Mesh on the Pins

Page | 86
 Chapter Three: Stopper Mechanism

❖ Result

Figure 108: Stresses Applied on the Pins

According to shown figures, the maximum stress on the pin equals to 33 MPa which is too
safe as required in its application and too away from the yield strength of AISI 1045 -Pin’s
Material-.

On the other hand, three components of the stopper mechanism are subjected to a static loading,
even resulted by mechanism wight, or resulted by a static applied force.

1. Fixed Plate Simulation

❖ Simulation Setup

The fixed plate is simply fixed with the bed by welding as

illustrated previously, it is subjected to preloaded force made by spring
at the neutral mode. During impact, it is subjected to the maximum
force exerted on the system and applied by the spring itself, this force
has been illustrated by the simulation made previously on the spring
element which equals to 30354 N.

Figure 109: Fixed Plate Simulation Fixation

and the Applied Force

Page | 87
 Chapter Three: Stopper Mechanism

❖ Result

Figure 111: Fixed Plate Factor of Safety Distribution Figure 110: Stresses Applied on the Fixed Plate

As shown in Figures, the design considerations ensure a factor of safety of 2.6 and the
static simulation shows a maximum stress lower than the yield strength of the fixed plate material
AISI 1020.

2. The long Rods

❖ Simulation Setup
As illustrated previously, the long rods are subjected at a specific position by a static load
made by the stopper mechanism weight 1500 N distributed on the four rods 375 N each. It is fixed
by welding with the impact plate and go through the fixed plate holes.

Figure 112: Rod Simulation Fixation and Applied Load

Page | 88
 Chapter Three: Stopper Mechanism

❖ Result

Figure 114: Rod Factor of Safety Distribution Figure 113: Stresses Applied on Rod

As shown in Figures, the design considerations ensure a factor of safety of 31 and the static
simulation shows a maximum stress lower than the yield strength of the fixed plate material AISI
1045.

In some cases, this factor of safety is considered as a big value, but in this case, it is suitable
for the other neglected conditions like bed vibrations and geometric constraints which are too
difficult to make simulations according to them.

3. Pulleys Shaft
❖ Simulation Setup
On the other hand, like the rods, the shaft shares the same loading applied by the
mechanism weight 1500 N. This time, the loading is distributed to different two specific regions
at where the shaft and the above rods is connected by welding.

Figure 115: Shaft Simulation Fixation and Applied Load

Page | 89
 Chapter Three: Stopper Mechanism

❖ Result

Figure 117: Shaft Factor of Safety Distribution Figure 116: Stresses Applied on the Shaft

As shown in Figures, the design considerations ensure a factor of safety of 17 and the static
simulation shows a maximum stress lower than the yield strength of the fixed plate material AISI
1045.

In some cases, this factor of safety is considered as a big value, but in this case, it is suitable
for the other neglected conditions like bed vibrations and geometric constraints which are too
difficult to make simulations according to them.

Page | 90
CHAPTER FOUR
 The idea of this program is based on a counter function. Whenever a billet passes in front
of one of the sensors, the counter value increases by one. Based on the counter value, the billet
position (and direction of motion) can be known, and consequently a new order is given (see Figure
(119)). The two hot metal detectors (HMD 1, HMD 2) are used in this system as a starting gate
and an ending gate, indicating the process beginning and stopping the process, while the first
pyrometer measures the temperature of the billet before starting to process to make sure the billet
has the suitable temperature. Additionally, the reverse hot metal detector (HMD R) is used to give
a signal when the billet reaches the end of the line to reverse the motors direction, while the two
temperature sensors (TS 1, TS 2) see the billet before each rolling hit in order to increase the
counter function required for the next order. The program is built of a set of functions, some of
them are auxiliary functions (e.g., to filter the sensor reading, or to count the number of billets),
and some are the main driving functions. A table of the used inputs and outputs by the PLC to run
the program is displayed next, followed by a descriptive block diagram that only serves as a quick
explanation of the process, and finally a set of the main functions of the program and their
description. Look Appendix (A).

Please note: to differentiate between the two different outputs on the same motor (for two
opposite directions of motor rotation), the rotation of the rollers towards the rougher is given a
positive value (1), while the rotation of the rollers towards the stopper -away from the rougher- is
given a negative value (-1), which is just a nostation.

Table 16: Inputs and Outputs of the Automated System

Inputs Description Outputs Description
Motor moving rollers on line 0
TS 0 Temperature Sensor 0 M0
(furnace exit)
TS 1 Temperature Sensor 1 M 1&3 Motor moving rollers on lines 1&3
TS 2 Temperature Sensor 2 M 2&4 Motor moving rollers on lines 2&4
HMD 1 Hot Metal Detector 1 M5 Motor moving rollers on line3
HMD 2 Hot Metal Detector 2 M6 Motor moving rollers on line4
Hot Metal Detector
HMD R Billet Order Billet ordering alarm
(Reverse)
Alarm Siren alarm

Page | 92
 Chapter Four: Automation

Figure 118: Block Diagram of the Automated System

Page | 93
 Chapter Four: Automation

To start the program, the user enters some

data using the HMI. The program then uses this
data as initial variables in order to take actions.
The program runs in 2 separate modes: the first
mode is the default one, where the program does
not allow another billet to enter the process
unless the current billet is finished or about to be
finished. The second mode is activated if the
required cycle time is too short, and hence the
program overlaps two billets in a certain
sequence. The present flowchart explains the
beginning of the process.

Page | 94
 Chapter Four: Automation

After choosing the

mode, the entering billet starts
the counter that was explained
earlier. The program is provided
with two counters, the program
can only deal with two billets at
the same time, therefore there is
a counter for even billets and a
counter for odd billets. The
following flowchart explains
how the counter function works,
showing when it increases, and
later on a flowchart explains the
actions taken based on the
counter value. Keep in mind that
CV1 is the counter value for the
odd-billet counter, and that the
delay at CV1=13 is to ensure
that the billet has reached the
following rolling stand.

Page | 95
Chapter Four: Automation

Page | 96
 Chapter Four: Automation

Based on the counter values, the PLC gives the order to the motors to rotate the rollers in
certain directions. All motors are optimally controlled in order to work only, when necessary,
either to push the billet towards the rougher, or to help withdraw the billet from the rougher, these
directions are given the values 1 and -1 consequently. However, the motors that rotate he rollers
at the furnace exit (M0) are constantly running, unless there is an error with the exiting billet,
whether in its temperature, or due to its early arrival. This special case for M0 is to prevent the
collision of the exiting billet with stationary rollers, as these rollers help in the billet withdrawal
from the furnace, while the worker that sends the billet out of the furnace is placed in a separate
room for the furnace control and cannot see the rougher directly. The motor running conditions
are explained in the upcoming flowchart. Keep in mind that there is a set of motors (M5) that only
work under certain conditions, where the second groove of the rougher rollers are used, otherwise
M1&3 are used.

Page | 97
Chapter Four: Automation

Page | 98
Chapter Four: Automation

Page | 99
Chapter Four: Automation

Page | 100
 Chapter Four: Automation

Figure 119: The Layout After Automation Page | 101

 Chapter Four: Automation

According to the layout after automation the following illustration does not take into
consideration the classification of sensor’s types, it illustrates the order of the sensors implemented
on the production line.

Figure (120) illustrates the temperature sensor after furnace and highlights the sensor’s
sensing head and the slot made for the sensing line. An inner slot is made in a metal plate for the
sensor to be fixed on, this slot gives the
flexibility to the sensor to be adjusted
horizontally because the slot made for the
sensing line is adjusted frequently during
maintenance.

This temperature sensor is implemented

on the layout for measuring the billet
temperature preventing the billet from entering
the whole process only if its temperature value
lies between predetermined range of temperature
values to maintain the final product good quality. Figure 120: Temperature Sensor after Furnace

Figure (121) illustrates the hot metal

detector implemented on line 1, highlights the
sensor’s body and the slot made for the sensing
line. The hot metal detector is fixed on a plate
welded on the line 1, a slot is made in the
detector body for changing the angle of view.

This hot metal detector is implemented

on the layout to mark the start of the process.

Figure 121: Hot Metal Detector on Line 1

Page | 102
 Chapter Four: Automation

Figure (3) illustrates the temperature sensor

before the rougher and highlights the sensor’s
sensing head and the slot made for the sensing line.
An inner slot is made in a metal plate for the sensor
to be fixed on, this slot gives the flexibility to the
sensor to be adjusted vertically because the hole
made for the sensing line is adjusted frequently
during maintenance.

This temperature sensor is implemented on

the layout for detecting the billet position at any
stage in the roughing process before the rougher. Figure 122: Temperature Sensor before the Rougher

Figure (4) illustrates the temperature

sensor after the rougher and highlights the sensor’s
sensing head and the slot made for the sensing line.
An inner slot is made in a metal plate for the sensor
to be fixed on, this slot gives the flexibility to the
sensor to be adjusted vertically because the hole
made for the sensing line is adjusted frequently
during maintenance.

This temperature sensor is implemented on

the layout for detecting the billet position at any
stage in the roughing process after the rougher. Figure 123: Temperature Sensor after the Rougher

Page | 103
 Chapter Four: Automation

Figure (124) illustrates the hot metal

detector implemented on line 2 and 4, highlights
the sensor’s body and the slot made for the sensing
line. The hot metal detector is fixed on a plate
welded on the line 2, a slot is made in the detector
body for changing the angle of view. Another slot
made to the fixed plate for changing the height of
the detector.

This hot metal detector is implemented on

the layout to reverse the billet direction of motion
Figure 124: Hot Metal Detector for Line 2 and 4
on line 2 and 4.

Figure (126) illustrates the hot metal

detector implemented on line 6, highlights the
sensor’s body and the slot made for the sensing line.
The hot metal detector is fixed in a housing as shown
in Figure (125) which is fixed to the ground that is
for protecting the sensor from this harsh section of
the line.

This hot metal detector is implemented on

the layout to mark the end of the roughing process.
Figure 126: Hot Metal Detector on Line 6

Figure 125: Housing of Hot Metal Detector on Line 6 Page | 104

 Chapter Four: Automation

7 8
1

2 3

4 6
5

Figure 127: The Electric Panel of the Automated System

Page | 105
 Chapter Four: Automation

1. This is considered as the control unit of the system which consists of three modules:
• Power Supply
• CPU
• Analog Input Module
2. Ten relays for controlling the output signals of the line motors.
3. A relay supplies the power for the previous ten relays, and it is controlled by a
mechanical switch to select whether the manual or automatic control.
4. Ten electrical rosettes used to wire the output of the motors.
5. Six electrical rosettes used to wire the input of the sensors:
• 3 analog inputs (Temperature Sensors)
• 3 digital inputs (Hot Metal Detectors)
6. Power rosette used to get the power for the system (220 V).
7. One pole circuit breaker protects the system from overloading.
8. HMI (Human Machine Interface) used to interact with the system.

Page | 106
 Chapter Four: Automation

The automation project human machine interface consists of five pages, categorized into four
types:

• Control
• Observation
• Statistics
• Test

The upcoming illustrations will discuss in detail each page elements as well as the changes during
operation.

1
7
4

5
5 3

Figure 128: Control Page

Page | 107
 Chapter Four: Automation

There are elements common in all pages (Fixed Template):

1. Time Clock and Date which are editable if they are not correct.
2. Five buttons used for toggling between HMI pages.
3. Logo of the facility (EL MARAKBY Steel)

On this control page there is input section (4) must be filled by the operator at the start of every
working shift, this section contains:

• Gap Time: Time interval between the billet under roughing process and the billet which
finished the roughing process, this gap time is set for process safety.
• Order Delay Time: This time is estimated to simulate the delay time resulted by the human
factor while the operator starts to order a new billet.
• Required Rolling Time: This time is set as input at the start of the working shift, then it is
measured from rolling process at the end of the line.
• Error Time Threshold: This time is set by the operator for every single section of the
process to not be exceeded other than, there will be an error.
• Upper Temperature Limit: The maximum value of temperature for the billet to not be
exceeded, and the billet must wait to cooldown before entering the process if its
temperature exceeds this value.
• Lower Temperature Limit: The minimum value of temperature for the billet to not be
receded, and the billet must be eliminated from the process if its temperature recedes this
value.

Section (5) illustrates the controlling buttons as follows:

• Start/Stop Button: A button controls the execution of the automation program.

• Run/Pause Button: A button pauses the automation program at its position if there is an
error in the process to deal with and runs the automation program from the last position it
is paused at.
• Groove 2 Button: A button which is activated only if the roughing process is operated using
left grooves of the rollers.
• Reset Button: A button resets the automation program to its initial position if there is an
error in the process to deal with and already has been solved manually.

Page | 108
 Chapter Four: Automation

• Automatic/Manual: This shows the condition of the system (Automatic or Manual), which
is connected to the mechanical switch illustrated previously.

Section (6) illustrates process buttons as follows:

• Error Cancellation Button: This button is for forcing the system not to show any errors
occur.
• Mode 2 Cancellation Button: This button is for forcing the system to cancel mode 2 if it is
activated or if it will be. The lamp next to this button lights green if mode 2 is activated.
• Billet Order Button: This button is used to order the billet by the operator using HMI.
• Line Status: This Lamp shows the status of the roughing line.

Section (7) illustrates the procedure number, as the system has a total of thirteen procedures, those
two alternative boxes show the number of the procedure the operation is held on.

Figure 129: Control Page with Changes

As shown in Figure (129), the system records an error during procedure 3 (The billet stuck in the
rougher), so an error red lamp flashes and the line has been stopped, so its lamp goes red.

Page | 109
 Chapter Four: Automation

Figure 130: Control Page after Pressing the Errors and Mode 2 Cancellation Buttons

There are two pages for observation during the process, on for the sensors, and the whole
roughing line.

1 2

Figure 131: Sensors Page Page | 110

 Chapter Four: Automation

Section (1) illustrates the group of hot metal detectors implemented on the line; each sensor’s lamp
lights green when it detects a billet.

Section (2) illustrates the group of temperature sensors implemented on the line; each sensor shows
its measured value on the box next to it with the clarification of the control upper and lower
temperature values for the furnace temperature sensor. Two sliders are set for the temperature
sensors before and after the rougher.

Figure 133: Sensors Page during Operation

Figure 132: Error due to billet's temperature which recedes the lower value
Page | 111
 Chapter Four: Automation

Figure 134: Signal for the Billet that Exceeded the Upper Temperature Value

Figure 135: Roughing Line Layout while Automatic System is Activated

Page | 112
 Chapter Four: Automation

The gray rectangles represent the condition of motors; light green when motors are running.
The blue triangles represent the condition of the hot metal detectors; light green when detectors
are activated. The red circles represent the condition of temperature sensors; light green when
sensors are activated. The gray lamp on furnace lights green when ordering a new billet.

The control room lights red when the automatic system is applied and lights green while
using the manual system.

The counter buttons are used only in testing phase for the need of skipping any procedure
of the system’s thirteen procedures. The layout is supplied by arrows which appear during
operation, showing the direction of the moving billet.

Figure 136: The Roughing Line Layout During the Operation

Figure 137: The Layout Shows an Error because the Billet is Stuck on the Line

Page | 113
 Chapter Four: Automation

Figure 138: Statistics Page

Statistics page illustrates:

1. Daily and monthly downtimes; the daily downtime is shown only when the “End Shifts”
button is pressed while the monthly downtime is shown only on the first day of every
month.
2. Daily and monthly consumed billets; the daily consumed number of billets is shown only
when the “End Shifts” button is pressed while the monthly consumed number of billets is
shown only on the first day of every month.
3. Actual and required productivity; the actual productivity is measured from the roughing
line and the required productivity is measured from the end of total production line.

Page | 114
 Chapter Four: Automation

Figure 139: Statistics Page during Operation

This page is only used to check the motors’ condition before operating the automatic system. Each
group of motors has a button for running in specific direction.

Figure 140: Statistics Page during Operation

Page | 115
 Chapter Four: Automation

The most important note to take into consideration is that the main difference between manual
and automatic system is the running time of lines motors, as well as the total time of the roughing
cycle (it's considered as the time taken from entering line 1 until the stop before the 5th hit).

Stopwatch is used to record time intervals for each portion, and in order to make sure that
the data is valid and describes the variability of the manual control, the data was collected 6 times
for 2 different operators (A&B), 3 times each. Those intervals were taken separately in different
periods of time.
In manual control system Line 6 is always running, because the operators cannot handle the
complexity of the process and at the same time control this line. However, in both manual and
automatic control systems, Line 0 is always running to avoid any conflict with the billet exiting
the furnace, as this operation is executed by a human operator in a separated room.
The following time intervals are taken for each group of motors per one cycle of roughing process.
Therefore, for the lines that have continuous running condition, their minimum running time would
be equal to the total roughing cycle.
Table 17: Motors Time Intervals for the Manual System
Cycle Cycle 1 Cycle 2 Cycle 3 Cycle 4 Cycle 5 Cycle 6 Average
Line (sec) A (sec) A (sec) A (sec) B (sec) B (sec) B (sec)
Line 0 38 41 42 38 38 39 39
(continuous run)
Line 6 38 41 42 38 38 39 39
(continuous run)
Line 1&3 17 18 19 20 18 23 19
Line 2&4 23 25 26 30 35 36 29
Line 5 5 5 12 10 8 7 8
Total roughing 38 41 42 38 38 39 39
cycle

Table 18: Motors Time Intervals for

the Automatic System
Cycle Cycle
The analysis is done on an HMI video of the billet Line (sec)
automatic valid run and the presented time intervals are Line 0 (continuous run) 37
generated. Line 6 20
As the automatic system takes the decision of operating the Line 1&3 19
motors at the same position every single time then there is no Line 2&4 24
variability in the cycle or its sections. Line 5 10
Total roughing cycle 37

Page | 116
 Chapter Four: Automation

1. Reducing the idle time of motors.

Figure 141: Comparison between Manual and Automatic System

• Reducing 19 sec. of running for motors on line 6

• Reducing 5 sec. of running for motors on line 2&4
• The given time reduction can be improved by further tuning. Which in return reduces the
cost of electricity in this sector of the production line.
• For line 5 motors, their running time increased 2 sec. per cycle, but this can be eliminated
by further tuning of the automatic system.

2. Increasing the speed and stabilizing the process.

As previously shown, that the automatic system has entirely eliminated the variability in the
process, resulting in steady productivity output from this sector. Moreover, the total roughing cycle
is reduced 2 sec and can be further reduced, although the roughing process is faster than the rest
of the production line most of the time. However, this increase in productivity of the rougher sector
gives the potential to increase total productivity if there is any improvement made on the rest of
line in the future, which is already planned.

Page | 117
 Chapter Four: Automation

3. Conserving the furnace.

Steady billet withdrawal from furnace sets the furnace temperature to a constant value, and
thus significantly reducing the technical issues resulted from frequently changing the temperature.

4. Maintaining high quality.

The automatic system controls the billet temperature entering the process to a tight range, this
helps in the quenching process, which is done on the final product, thus resulting in improving the
final product quality and reducing the variance in quality.

5. Saving labor
Highly skilled labor is no longer needed in the control operation, due to the reduction in the
number of steps needed from the operator to interfere in the automatic system, that is compared to
the manual system, since the operator now only interferes when there is a technical error, also
those steps are far less complex. Besides, the operator would be far more comfortable at the control
operation.

6. Keeping breakdowns to minimal.

The most common type of breakdown in the process is that the rollers of the roughing stand
don’t bite the billet properly (the billet slips) and this happens due to 2 main reasons

• The billet doesn’t have enough speed. This is eliminated in the automatic system, since the
billet moves each time from the same point on the line, and it’s the furthest point from the
rougher to ensure the billet gains maximum speed.
• The billet has a very high temperature. This is also eliminated in the automatic system,
since the billet is not allowed to get into the process before cooling down to the upper
temperature limit set in the system.

7. Adding extra features.

There are more options added to the process due to the implementation of an automatic system,
like knowing the total downtime (daily and monthly) and knowing the number of billets entering
the system (daily and monthly). Those were not determined in the manual system, and for future
planning, the system can be modified to get more options.

Page | 118
 Unstable productivity was the main problem in the roughing process operated on a three-
high rolling mill, as well as energy and time losses, which affected the efficiency of the process
drastically. And due to the difficulty in optimally controlling the process by the available
technicians, a number of skilled workers were assigned to control the roughing process. All that
increased the total cost of the process, whether due to the wages for the mentioned workers, or
other parameters caused by the waste in time and energy.

In order to overcome the mentioned problems, it was decided to change the system from
manual to automatic, along with some mechanical modifications to evade the present waste.
Accordingly, the process was studied carefully, taking into consideration all possible technical
errors occurring during the process, the idle time produced, and the maximum waste during the
whole operation. Based on the gathered data, a mechanical spring was designed to avoid the time
and energy wastes, which were originated to stop a running billet and change its direction. More
importantly, a complex yet easy-to-use program was developed to control the process optimally
instead of the workers, which can likewise understand any given technical error, dealing with it
temporarily while giving an alarm till an operator interferes and fixes the problem. For
implementing the program, an electric panel was designed by the factory for the PLC which carries
the program, along with other modules and electric components that supports the PLC’s inputs and
outputs. Further modifications were done on the production line in order to replace the worker’s
observation with electrical feedback, which was achieved by the means of a set of sensors (3
pyrometers and 4 hot metal detectors), along with their temporary fixations on the line.

The implementation of the new automated system was tested and gave rewarding results.
The stable productivity was the most important outcome of the new system, as it no-longer depends
on the technician’s skills in handling the machine, as well as the constant working time per cycle
for each equipment, reducing their idle working time, and thus increasing their life time.

The implementation resulted in:

1. Reducing the idle time of line 6 motors by 25 minutes/hour.

2. Reducing the idle time of lines 2&4 by 6 minutes/hour
3. Increasing the process speed by 2 seconds

Further upgrade can be achieved through:

1. Tuning the PLC program for shorter cycle time

2. Adjusting the sensors’ fixations to give more precise readings
3. Placing the stopper mechanism to reduce energy waste
4. Increasing the furnace capacity to achieve the required production rate

Page | 119
• Further tuning is needed for the implemented automatic system to reduce the running times
of motors and total roughing cycle time, which can be achieved by adjusting the current
locations of the sensors.
• The furnace could be replaced to increase its capacity to meet the productivity of the
production line.
• The furnace could be automatically controlled to remove the human factor entirely from
the whole process.
• The stopper mechanism previously designed in this book can be implemented to reduce
the total roughing cycle time and energy waste.
• The information obtained from the statistics page can be tracked and used to know the
reasons for breakdowns and try to eliminate those reasons.
• The automatic system can be improved to add more features, such as knowing when to
decrease the gap between the rollers in the stand.

Page | 120
[1] K. Hashemnia, “Experimental study of the effect of temperature on the coefficient of
restitution of steel balls impact to some industrial metal sheets at elevated temperatures,”
Powder Technol., vol. 368, pp. 170–177, 2020.

[2] D. Fuller, “Coefficient of Friction,” columbia university, New York, 2011.

[3] B. T. Werner, B. R. Antoun, and G. B. Sartor, “Thermal degradation of extension

springs,” Conf. Proc. Soc. Exp. Mech. Ser., vol. 2, 2016.

Page | 121
Page | 122
Appendixes

Page | 123
Appendixes

Page | 124
Appendixes

Page | 125
Appendixes

Page | 126
Appendixes

Page | 127
Appendixes

Page | 128
Appendixes

Page | 129
Appendixes

Page | 130
Appendixes

Page | 131
Appendixes

Page | 132
Appendixes

Page | 133
Appendixes

Page | 134
Appendixes

Page | 135
Appendixes

Page | 136
Appendixes

Page | 137
Appendixes

Page | 138
Appendixes

Page | 139
Appendixes

Page | 140
Appendixes

Page | 141
Appendixes

Page | 142
Appendixes

Page | 143
Appendixes

Page | 144
Appendixes

Page | 145
Appendixes

Page | 146
Appendixes

Page | 147
Appendixes

Page | 148
Appendixes

Page | 149
Appendixes

Page | 150
Appendixes

Page | 151
Appendixes

Page | 152
Appendixes

Page | 153
Appendixes

Page | 154
Appendixes

Page | 155
Appendixes

Page | 156
Appendixes

Page | 157
Appendixes

Page | 158
Appendixes

Page | 159
Appendixes

Page | 160
Appendixes

Page | 161
Appendixes

Page | 162
Appendixes

Page | 163
Appendixes

Page | 164
Appendixes

Page | 165
Appendixes

Page | 166
Appendixes

Page | 167
Appendixes

Page | 168