Electric and Automation

Since SMS stepped into the electrical & automation field in the 1980s, its E&A business has been growing continuously, and now EA Division is the one of the market leaders in supply of electrical & automation system solutions for the metallurgical industry. In order to provide localized service and support for local customers, SMS established an Electrical & Automation Division in September 2002, in Beijing, China.

The Electrical & Automation business in SMS China covers the iron & steel, aluminum and copper industry. The control system is widely applied in steel-making, caster, hot & cold rolling mills and processing lines.

The SMS group’s Electrical & Automation Division is committed to being an EA system integrator with its business scope covering the whole product range in the metallurgical industry. The Division provides its customers withconsultancy, engineering, equipment supply, commissioning services, technical support and maintenance service for power supply, drive systems, basic automation systems, technical control systems, and level 2 up to Level 3 system.

Along with increasingly intense competition on the metallurgical market, customers have an increasing demand to improve the plant efficiency and product quality of their existing production lines. SMS Electrical & Automation Division continuously builds up its competence for the modernization of existing plant. By upgrading the electrical & automation systems, it helps its customers improve their overall process technology and enhance their products’ competitiveness on the market.

X-Pact®-A powerful automation system
  • Level-3 systems. L3 systems control the production of the entire plant by converting the customers’ orders into production measures in a specific plant. They also make production planning in an optimized way and monitor the production of the individual equipment. In the event of production disturbances, changes in planning can be made flexibly and in real time. In addition, the L3 systems distribute the primary data (PDI) to all L2 systems and receives the current production result data accordingly. Then the L3 systems can put the data on file and produce reports. The overriding aim is to achieve the largest possible output, optimize plant utilization and lower inventory while meeting the customers’ requirement about the delivery date. Moreover, replacement of parts such as rolls can be managed and planned in line with the demand.
  • Level-2 systems. The L2 systems include various mathematic models and process parameter lists, which are the outcome of the longtime experience of SMS in processes. On the basis of the primary data (PDI), the L2 systems generate the set point values needed by the L1 systems, and send the values to the L1 systems according to time and product requirements, so as to make sure that the products reach the best metallurgical requirements and geometrical properties.  The actual measurement values received from the L1 systems are used for automatic adaptation of the process models and compiled into production logs. Furthermore, the L2 systems transfer production data back to the L3 systems. 
  • Level-1 control systems. Technological control systems are designed to ensure excellent technological and functional implementation of the set point values generated by the L2 systems by using hydraulic and electronic actuator systems. Moreover, other essential properties of the L1 systems, such as maximum functional availability, a high degree of process sequence automation on real time basis, and efficient service functions, ensure the best possible dynamic performance and control precision of the mechanical, drive-related and hydraulic equipment.
  • Level 0 basic automation. From the Ethernet and field-bus design to the selection of various I/O modules, instruments and sensors, our hardware engineers use the most advanced utilities and technologies. In our hareware design, we adopt the most updated real-time EtherCAT technology, and widely use E-PLAN technology.
Power supply and drive system. Our Electric and Automation Division provides engineering, selection and supply for the power supply and the drive system, which includes switchgear cabinets, transformers, power compensators, harmonic filters, diesel generators, UPS and VVVF drive system, as well as constant speed drive system (MCCs).
 
Perfect combination of quality and cost
Our expertise and longtime experience ensure an accurate control, fast response, reliability and safety of the X-Pact® electric and automation system. Our switchgears, drive cabinets, control cabinets, operating devices and various other panels and boxes are all supplied by internationally renowned electric manufacturers. In particular, we have established a joint venture to assemble and manufacture our in-house designed cabinets based on SMS quality standards. The interlinked workflow of engineering, procurement and manufacturing reduces costs and shortens the delivery time.
 
Plug and Work
Plug and Work is a distinctive concept for testing of automation systems developed by SMS. In contrast to conventional system test, plug and work expands the test in the scope and depth: By simulating plant environment and mechanical equipment, all the automation solutions, such as process models, control systems and technological applications are tested in advance in the test center, to make sure that the system conforms to the future field configuration before delivery. The commissioning time on-site is reduced dramatically to achieve a steep ramp-up curve. The Plug and Work testconcept is adopted throughout the development of our X-Pact® automation control systems.
 
Service
In addition to providing customers with regular maintenance, equipment optimization, troubleshooting, equipment monitoring and other basic services, we also provide professional technical support and services including:
  • 24-hour hot line
  • Remote diagnosis service
  • Spare parts service
  • On-site technical support
  • Updating/upgrading

Steel
Our X-Pact® automation system is widely used in various fields of the iron and steel industry. It is well integrated with the customers’ L4 and L3 systems to enhance the informatization of production management.
  • Steelmaking
    There are different furnaces, such as EAF, BOF, and AODon the market, and in future, intelligent steelmaking will be the mainstream and general trend in the industry. SMS Electrical & Automation Division provides different Electrical & Automation solutions for these metallurgical processes, and using its longtime experience, has developed intelligent models for different processes, which have been successfully applied in many famous steel mills across the world and play an vital part in improving process flow, enhancing efficiency, and reducing operation cost.
  • Continuous casting
    Casting technological models and control systems play an important role in the casting production. Our mold level control and dynamic solidification control ensure the best surface quality and inner metallurgical performance of the slab. The mold monitoring system prevents the breakout effectively and reduces longitudinal cracks. Due to the special operating environment, casting equipment poses stricter requirements for the stability and reliability of the electric and automation systems.
  • Hot Rolling Mill
    There are mainly two types of hot rolling mills-Hot Strip Mill and Hot Plate Mill. SMS has developed tailor-made solutions for both production lines to help customers attain the optimal cost-effective investment. We can provide X-motion compact PC based solutions as well as Embedded PC based solutions for control systems. In the process control, the combination of CVCplus® and PCFC models improves the product accuracy and surface quality. It enables customers to achieve the optimized product profile and flatness.
  • Cold Rolling Mill
    Considering the process requirements, we provide single stand control (4 high, 6 high, 20 high) solutions, two stands control solutions as well as tandem cold rolling mill solutions.
    The technological model of the CRM control system calculates the set up values for strip rolling according to the mill stand state. Combined with technological control system, it can harmonize rolling force, torque and speed to obtain the best thickness and flatness. CVCplus® work roll, intermediate roll and backup roll expand the control range of flatness, while the flatness control system (FCS) keeps the tolerance at the minimum.
  • Processing Line
    Processing line processes include pickling, cleaning, annealing, coating, hot dip galvanizing, plating (tin, zinc, chromium), leveling, trimming, cold rolling material slitting and cross cutting, recoiling, preparation line, silicon steel processing line and hot rolling material crossing. All are covered by our X-Pact® electric and automation system.
Our turbulence pickling model controls the temperature precisely and the density of acid fluid accurately to shorten the pickling time effectively and reduce the energy consumption by a large margin.
In line with various processing lines, different product libraries have been developed to meet the technological requirements of different equipment.

Aluminum
Aluminum rolling covers hot rolling, cold rolling and processing line as well as aluminum foil. X-Pact® electric and automation solutions cover all the functions used for aluminum HRM, CRM and processing lines, including open loop control and closed loop control as well as monitoring functions. It ensures perfect integration of power distribution, drive system, instrument and automation, production schedule and mechanic equipment to enable the continuous optimization of process parameters, product quality and productivity.
  • Aluminum Hot Rolling Mill:
    Rolling force, torque and rolling speed should be harmonized to obtain stable product quality and productivity, and in view of this requirement, our  technological process models are integrated into the automation system. The T-Roll® models calculate the pass schedules by simulating the roll gap conditions to determine the exact number of rolling passes for various strips. Considering the temperature limits of different product grades, the dynamic technological control makes the product thickness, profile, flatness and width to be exactly in line with the set up values.
  • Aluminum Cold Rolling Mill:
    Besides the technologies mentioned above, cold rolling mills also benefit from the perfect combination of CVCplus® and X-Pact® flatness control. Special Contour Rolls (SCR) with various contours ensure the ideal flatness even using the cold rolls after roll change. Hot Edge Spray (HES) system developed by SMS is specially designed for thin-gauge rolling. As a reliable system, HES prevents tighter edge by spraying hot rolling oil precisely over the work roll. Furthermore, our flatness measurement roll and flatness control functions help the strip maintain good flatness, which makes the high-quality of aluminum product.
  • Aluminum Foil Rolling Mill:
    Our X-Pact® aluminum foil rolling solution outperforms the conventional control in the field of aluminum foil production, and can optimize the thickness and flatness simultaneously. Considering the rolling process as a whole, the system obtains the best thickness and flatness through the interaction of rolling force and work roll bending. Moreover, it controls the thermal crown of work rolls dynamically to get stable trend of the strip during rolling, and ensures more efficient productivity and better quality.
  • Aluminum strip processing line:
We have rich experience with the aluminum strip processing, which are applied in the X-Pact® automation system. Our electric and automation solutions for processing lines cover the whole process, which includes cleaning, annealing and coating to ensure sustainable and stable product surface quality.

Copper
We’ve been enhancing and expanding our business in China’s copper industry in recent years. Our automation system has been successfully used in the hot rolling mill and cold rolling mill for copper. CVCplus® and X-Pact® flatness control ensure optimal copper strip thickness and tolerance. SCR backup rolls and EDC® work rolls greatly improve the edge quality of copper strip. T-roll® model calculates the exact passes required to obtain the best rolling process and efficient productivity. The copper strip drying system can effectively remove the surface stains.