Robots in metallurgy: examples of use

Self-propelled robotic platform designed for predictive diagnostics of the main equipment

Pipe inspection

One of the relatively new solutions in domestic metallurgy is the use of a robot that inspects the inner surface of pipes. Pipes in metallurgy are usually several tens or even hundreds of meters long, and a person cannot safely reach any section. Then a robot is launched into the cavity of the pipe - outwardly, it is a kind of cart on four wheels, which has a movable mast with a camera.

The cart is quite heavy: its weight exceeds 20 kg. This figure is due to the peculiarities of the equipment and the need for reliable adhesion to the coating. Behind it, a robot cart drags several hundred meters of cable - it allows you to broadcast an image from the camera. And the camera here is modern and technological: 10x optical zoom and 12x digital zoom are used - this makes it possible to accurately determine even the smallest cracks and damage to the internal coating of the pipe.

The analysis of the resulting image is carried out by special software: the program looks for damage and blockages, studies their criticality and size. Also, automation analyzes the deformation of the pipe and its position in space.

So that specialists can accurately determine the problem area of ​ ​ the pipe, the robot trolley records the logs of the distance traveled. This allows engineers to quickly and correctly identify the area requiring repair or replacement.

The development of the robot, of course, costs money, but ultimately the metallurgical enterprise achieves savings: earlier, when only a person could inspect pipes, it was necessary to dismantle one or another section of the pipe to study it. Today everything is simpler: I launched the robot into the pipe - after a few minutes I got the result.

The information collected by the robot is processed and visualized for human decision-making

Site Walk-Around

Another scenario for using robots in production is bypassing (but rather bypassing) workshops and diagnosing units and units. Such diagnostics (it is called predictive) help determine the state of a particular mechanism and give a signal to fix the problem, if any. In metallurgy, such a robot can use sound imaging technology. What does it mean? For example, the bearing is normally silent. If it becomes unusable, deformation begins inside the bearing, which causes noise and vibrations - it is these that the robot catches using sound visualization.

The machine is equipped with sensitive microphones and a camera: the former detect breakdowns, and the camera takes a picture of a problem node or unit. The microphones are tuned to cut off extra extraneous sound and capture only noise inside the bearing.

So far, this is only the "sound" part of sound visualization. Then, using the software, the recorded sound is translated into an image, which is compared with the reference one taken from a properly functioning node. If the images do not match, it is time to think about replacing the bearing. Such a system allows you to make more accurate forecasts and minimize downtime.

Crawler robots are still in development - employees of the enterprise deliver a sound visualization system to the point manually. However, already now companies are working to install the system on wheels, which will make it possible to make an automated bypass of workshops. The robot eliminates errors caused by the human factor, and can work almost continuously - its implementation will increase the accuracy of measurements and diagnostics. Such self-propelled platforms, by the way, are already used - so far in other workshops. The impressions are positive: the car was able to independently map the premises and make a test bypass.

The work of a robot television inspector

Robot destroyer

One of the enterprises will soon use a robot with such an unusual name. It will help people and replace them in dangerous jobs in the electric furnace shop. Outwardly, it resembles a hybrid of an excavator and a beetle: a huge yellow machine on four legs breaks the slag crust and lining masonry with a "sting" when servicing stoves. The use of the robot significantly increases safety in production: if earlier, during hot repairs, employees went directly into the furnace and broke the crust with jackhammers, then soon the robot-destroyer will do this.

Plasma quenching

A new pilot project will also soon be launched at NLMK's Lipetsk site - a robot for plasma hardening of wheelsets of special rolling stock (iron and slag). During the operation of wheelsets, defects are formed on their surface, which are periodically removed mechanically to restore the profile of the wheel. However, as a result of turning, we are forced to remove the upper, most hardened metal layer by the manufacturer. Therefore, to increase the strength of the parts after turning, we again subject the wheelsets to hardening, which increases their usability by an average of 1.5 times.

The robotic complex automatically rotates the wheel pair and subjects its surface to rapid heating, which ensures self-sealing of the surface layer.

The installation of a robot for plasma quenching will reduce the cost of working time of employees, improve the quality of quenching and eliminate defects that previously could appear due to the human factor.

Mobile point for controlling a robot TV inspector

So far, this is just the beginning - the practice of using robots proves its effectiveness, and we can say for sure that in the future the list of tasks that metallurgists transfer to machines will expand. Expectations and directions of work have already been formed: in addition to bypass and diagnostics, robots can be useful for sampling and environmental monitoring. Their wider use will increase the level of safety in production and will allow more human resources to be directed not to routine, but to solving specific and creative problems.

Photos provided by NLMK.