IoT platform for the continuous casting line

Story

SMS group is a global, leading partner for the metal industry. It is a family-owned business headquartered in Germany. Fast and flexible, SMS group develop individual and modular solutions – whether it’s the design of a new plant, Modernization, Digitalization, or Life Cycle Services.

Our goal

The goal of our first project with SMS group was defined as follows: to create a solution that will serve as an IoT-platform for the monitoring and quality assurance of the production in the continuous casting machine.

Solution
  1. Design
  2. Connection to OPC
  3. Custom widgets development
  4. Cloud setup
  5. On-prem setup
  6. Testing
Stack
  • ThingsBoard
  • Angular
  • Plotly
  • Cassandra
  • Docker
  • RaspberryPi
Solution

On-premise real-time process monitoring system.

Key functions and Use cases:

  • Real-time process monitoring
  • Customizable alarm system
  • Measuring data verification
  • Comparative analysis/trends in the production
  • On-fly quality check
  • Customizable rules engine

The customer provided us with all data sets required for continuous casting machine work emulation.

There are several separated dashboard implemented to provide different viewpoints on the production process by the casting of steel:

The “Process” dashboard shows a real-time machine performance using Rule engine. Customizable alarm system is developed as part of the solution. It allows to define case-based alarm notifications, that  are visible on the dashboard, as well accessible through smartwatches and smart glasses.

The “Maintenance” dashboard can be used effectively by shop-floor service personell, as it allows on-fly maintenancecheck at the rump up phases and during the production. We used Plotly library to render reports.

The “Quality” dashboard. The production of the continuous casting machine is constantly analyzed by quality assurance system. After the quality check, a report is generated, where the defects of the selected slabs are listed. The employees can easily access each error notification, read error description, see where the error occurred to analyse the reason behind it.

Result

The concept of the digital twin was successfully presented at METEC 2019 trade fair in Düsseldorf, Germany. The platform was greatly received by potential customers and got a lot of attention from the fair’s attendances. The product is being prepared for the installation at plants.

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