AISTech 2019 — Proceedings of the Iron & Steel Technology Conference

6–9 May 2019, Pittsburgh, Pa., USA

DOI 10.1000.377.132

Increasing Safety, Operation Efficiency and Process Reliability: Implementation of Robotized Tundish
Operations at Ternium Brasil

Franz Ramstorfer1, Leonardo Martins Demuner1, Fábio Luiz Lourenço1 Vinicius Cunha Aranda1,
Vinicius Sinhorely Oliveira1, Willian Junior Correa1, Eduardo Hernandez Duarte2 and Lúcio Mascarenhas Fernandes2
1
Ternium Brasil
Av. João XXIII s/n, 23560-352, Santa Cruz, Rio de Janeiro, Brazil
Phone: +55 21 2141 3034
Email: franz.ramstorfer@ternium.com.br
2
Vesuvius RJ
Av. Brasil 49550, 22631-450, Campo Grande, Rio de Janeiro, Brazil

Keywords: Continuous casting, Tundish operations, Robotics

INTRODUCTION

Industrial robots are being used in the automotive industry for many years now, but so far, they are only rarely being
implemented in the harsh environment of a steel plant. One major issue has always been the adaption of industrial robots and
its auxiliary systems like magazines or tools to this challenging environment in order to obtain the reliability requested by the
customer. However, in the last ten years more and more robot systems, which perform sampling-, measurement- and
handling tasks at the oxygen steelmaking- , electrical furnace- and continuous casting area were successfully installed
worldwide1 – 3.
In the continuous caster area, robots were mostly installed in the tundish area, since during manual tundish operations, the
operator is exposed to heat, dust, physical exertion and inherent danger from reactions inside the tundish or ladle or even
scull falling down from the ladle. Even though working in this tough environment, important operational tasks like

x Temperature measurement
x Hydrogen measurement
x Steel sampling
x Application of tundish insulation powder
x Ladle shroud manipulation
x Ladle shroud cleaning
x Ladle oxygen lancing

have to be performed in order to guarantee process stability and product quality.

In the first place, introduction of robotized tundish operations increases considerably the safety of the operational personnel,
since all tasks are performed remotely from an operator cabin outside the hazardous area, where a safe distance between
people and liquid steel is maintained.
As a second important factor, the increase in productivity and preservation of product quality should be mentioned.
Robotized tundish operations guarantee a fast and repeatable sequence start-up procedure during tundish filling since
application timing and -position as well as the amount and type of tundish insulation powder is pre-programmed and
automatically applied by the robots. A fast, safe and consistent ladle shroud handling including connection, disconnection,
cleaning and inspection of the ladle shroud reduces the period without steel flow to the tundish during a ladle change.
Maintaining a sufficient steel level in the tundish avoids slab quality issues related to inclusions or unnecessary changes of
the casting speed.

© 2019 by the Association for Iron & Steel Technology. 1291

Robotized tundish operations additionally increase the overall process reliability since measurement- and sampling tasks are
executed at a defined and repeatable location, probe immersion depth and pre-defined timing according production norms.
Process tractability of the casting process is enhanced as well, since all data of robot operations and quantity of
consumables are logged and stay available for further analysis and process optimization via Level 2 automation system or
Manufacturing Execution System (MES).
The present work describes the implementation of robotized tundish operations at Ternium Brasil using two robots for each
of the two continuous casting machines at our plant as well as a detailed overview of the main components, features and
operational performance of the system.

PROJECT SCOPE

In August 2017, Ternium Brasil (former thyssenkrupp CSA Siderúrgica do Atlântico) awarded Vesuvius with a turnkey
project of a robot system (Robotic Casting Technology - RCT) capable of executing seven tundish operations at both 2-strand
slab casters.
In the first project phase, four functionalities (temperature- and hydrogen measurement, sampling and powder application)
were implemented, since the functionalities, which involve ladle shroud manipulation, require the implementation of a new
ladle slide gate mechanism with integrated Ladle Tube Changer (LTC). The ladle modifications and the implementation of
the LTC system were accomplished in the second project phase between December 2018 and March 2019.
The robot system went in operation with four functionalities in May 2018 at CCM 1 and in November 2018 at CCM 2. The
necessary modifications of the casting platform were done during a planned maintenance shutdown of around five days.
System optimization, hot commissioning and operator training did not require additional caster down time. Finally, all seven
robot functionalities went in full operation at both casters in April 2019.

Robot system (RCT)

The location of the equipment on the casting platform has been engineered to ensure safe operational conditions, optimal
robot working sequences, and minimal modifications of the caster. Since the operation space of both robots is very limited,
the whole project was completely simulated in a virtual 3D-environment in order to optimize the position of the robots and
auxiliary systems like magazines and racks. Additionally, the robot movements, the accessibility of all magazines, racks and
tools and collision checks were simulated and verified in this virtual environment as well.
Even though extensive 3D-simulations were carried out, the robots were assembled and tested together with all tools,
magazines and consumables in the workshop of Vesuvius Belgium. In this controlled environment, programming of the robot
trajectories and testing of the complete automation package (functionalities of the tools, shrouds and safety mechanisms
including all failure scenarios) were done. Project team members of Ternium Brasil attended several workshop tests, where
functionalities and requirements were reviewed as well as an extensive operation- and maintenance training was addressed.
Figure 1(a) – (c) give some impressions of these workshop tests.

(a) (b) (c)

Figure 1. Testing of the robot system at the workshop of Vesuvius: (a) Insulation powder application, (b) Temperature
measurement, (c) Attaching a monoblock ladle shroud to the LTC.

1292 © 2019 by the Association for Iron & Steel Technology.

Figure 2 shows the layout of the robot system with all its main components. Generally, the robot system was designed to
fulfill several safety standards like the EN ISO 12100:2010 (Safety of machinery - General principles for design), ISO/TR
202218-1:2018 (Robotics - Safety design for industrial robot systems), EN ISO 10218-2:2011 (Safety requirements for robots
systems and integration) and ISO 13849-1:2006 (Safety of machinery - Safety-related parts of control systems).

The design of the robot system is based on two industrial 6-axis robots (Robot 1 (1) and Robot 2 (2)), which were especially
modified for the tough surrounding conditions at the casting platform. Both robots are protected with a specific sleeve to cope
with the steel plant environment, i.e. liquid steel splashes, heat, radiation and dust. Since both robots are standard industrial
robots from KUKA®, which are widely used in the automotive industry as well, spare parts availability and 24h technical
assistance is therefore no issue.
Robot 1 performs all ladle shroud manipulations and addition of tundish insulation powder at two tundish locations.
However, this robot does not have to support the ladle shroud permanently during casting, since the ladle shroud is supported
inside the new Ladle Tube Changer mechanism (LTC). The robot layout allows keeping the existing ladle shroud
manipulator as a backup solution, thus allowing for a smooth transition phase between manual and fully automatic operation
during commissioning.
The second smaller robot (2) handles the different probes, oxygen lancing of the casting channel in case of a non-free ladle
opening as well as the powder application at one tundish position. Both robots are equipped with a specific gripper (tool
changer) to grab different tools and transfer the proper media or signals through the tool (sampling with and without argon,
hydrogen measurement, temperature dip or any other specific media as oxygen if required). As a safety measure, the tool
changers stay clamped (self-locking) in case of air pressure failure.

14
12 1
6 7 2 3 11 5

8 13

10 10
4 9 9 4

1 Robot 1 2 Robot 2 3 Existing casting platform

4 Removable platform extension 5 Robot cell access door 1 6 Robot cell access door 2
7 Probe magazine 8 Probe bin / sample collection 9 Powder racks Robot 1
10 Powder racks Robot 2 11 Ladle shroud rack 12 O2 lancing equipment
13 Tool rack ladle shroud gripper 14 Rack for powder and probe tools

Figure 2. General layout of the robot system and its main components.

© 2019 by the Association for Iron & Steel Technology. 1293

The robot system was installed at the existing casting platform (3) after removing the actual operator cabin and relocation of
existing operator panels, power-, fluid- and gas lines. Since both robots induce additional static and dynamic loads into the
casting platform, the structure of the casting platform had to be reinforced. Figure 2 shows, that due to the implementation of
the robot system, the casting platform was extended with two mobile platform extensions (4), which can be easily removed in
the case of a caster maintenance involving segment exchange.
All robot movements take place inside a closed robot cell, which is separated from the casting platform by a fence with
controlled access via two access doors (5) and (6). According to ISO 13849-1:2006, the automated door lock mechanisms are
connected to a safety PLC, which permits or denies the operator entrance depending on the actual operation state of the robot
system.
During normal casting operation, there is typically no need for the operator to enter the closed cell since all consumables are
provided to the robot system from outside the robot cell. The robot takes the measurement- and sample lances from the probe
magazine (7), and after using, the lances are placed by the robot in the probe bin or sample collection bin (8), from where
they are discarded by the operator.
The tundish insulation powder bags (synthetic powder or rice ash bags of 10kg each) are loaded into movable powder racks
(9) and (10) from where the robot takes them via a powder tool. The ladle shroud rack (11) provides storage of up to six ladle
shrouds, which allows for long casting sequences without necessity of manual ladle shroud handling inside the robot cell
during casting operation.
Both robots grab tools from specific racks (12), (13) and (14). Figure 3 shows the assembled robot system of CCM 1 before
the start of the hot commissioning phase in May 2018.

Figure 3. Assembled robot system at CCM 1.

Ladle Tube Changer Mechanism (LTC)

Until the implementation of this project, the liquid steel flow between the ladle and the tundish was controlled by a standard
ladle slide gate and classic ladle shroud connected to a conical collector nozzle where argon sealing around this nozzle seat
was applied (see Figure 4a). However, robotized ladle shroud handling requires a different approach without using a ladle
shroud manipulator for sustaining the ladle shroud. Vesuvius´ LTC ladle tube changer mechanism is a ladle slide gate with
integrated ladle shroud change device to load and maintain the ladle shroud. Since the LTC mechanism permanently presses
the monoblock ladle shroud against the lower plate, the robot only need to load or unload the ladle shroud from the LTC (see
Figure 4b). Since there is no physical connection between ladle and casting platform during casting operation, free turret
movement in case of emergency evacuation is ensured.

1294 © 2019 by the Association for Iron & Steel Technology.

 (a) (b)

Figure 4. (a) Standard ladle shroud operation, (b) Monoblock tube in full LTC-operation.

Contrarily to the standard ladle slide gate mechanism, two hydraulic cylinders operate the LTC mecanism, whereas the larger
hydraulic casting cylinder (1) controls the slide gate and therefore the steel flow into the tundish (see Figure 5). The smaller
hydraulic tube change cylinder (2) enables switching between the conical collector nozzle (3) (conventional ladle shroud
operation using a manipulator) and the robotized operation using a monoblock ladle shroud (4). The possibility of switching
between these two operation modes allowed a seamless commissioning phase of the robotized ladle shroud handling since the
conventional operation mode using the ladle shroud manipulator was always available as a backup. In the first phase of the
LTC implementation, the hydraulic system and hydraulic cylinder support of the ladle turrets were modified in order to
operate the new LTC mechanisms as well as the original mechanisms at the same time. After these modifications, the LTC
mechanisms were installed one by one at each ladle. The modifications of the ladle were manageable and limited to the
adjustment of heat protection plates and the assembly of an intermediate adaptor plate.
As already mentioned, during this first implementation phase, the LTC was used as conventional ladle slide gate with conical
collector nozzle and ladle shroud manipulator. After the first implementation phase very little adaptions (exchange of a few
parts) had to be made in order to put ladle shroud handling by the robot in full LTC-operation.

1
3
4
2

Figure 5. Ladle Tube Changer mechanism (LTC).

The possibility of switching between the two operation modes provides a huge benefit in the case of a non-free opening ladle
where oxygen lancing is required to continue with the casting sequence. In full LTC-operation, the time span of open stream
casting (and therefore the negative impact on the steel quality) is reduced to a minimum, since oxygen lancing is done
through the conical nozzle and the monoblock ladle shroud remains mounted to the LTC. Therefore, the monoblock ladle
shroud stays ready for a quick change to the casting position after completing successfully oxygen lancing.

© 2019 by the Association for Iron & Steel Technology. 1295

From a slab quality point of view, LTC offers, comparted to the classic system using a conical nozzle and a gasket (1), a
much better protection of the steel flow against re-oxidation and nitrogen pick-up (see Figure 6). The improved sealing is
provided by flat contact surfaces between ladle shroud (2) and ladle slide gate plate (3) which are pressed together with a
high sealing force of approx. 1.5tons provided by integrated springs as well as argon sealing via a shielding groove (4). The
flat joint concept guarantees a perfect vertical alignment of the ladle shroud providing a symmetrical flow inside the tundish
and therefore contributing to product quality and steel cleanliness.

1 3

4 2

Figure 6. Conical ladle shroud connection vs. flat joint concept provided by the LTC.

LTC offers as an additional benefit the integration of the slag detection ring in the base plate contributing to a higher slag
detection availability and therefore to the process stability and product quality as well.
However, the biggest advantage of LTC is the fact that this clamping force of approx. 1.5 tons enables safe submerge ladle
opening during sequence casting. While a classic conical connection between collector nozzle and ladle shroud provides
limited clamping force, the flat connection of the LTC provides enough clamping force to withstand any blow back
occurrence during submerged opening. Submerged opening preserves the quality of transition slabs during ladle change and
therefore avoids downgrading and contribute to yield prime quality slabs.

TUNDISH OPERATIONS

As already mentioned earlier, the commissioning phase was split into two phases, whereas in the first phase four
functionalities of the robot system were available:

Temperature measurement
Temperature measurement is carried out on the right side of the tundish through a hole in the tundish cover near the stopper
of Strand 2 in case of CCM1 or Strand 4 in the case of CCM2. In order to accomplish the measurement task, Robot 2 grabs
the temperature tool from the specific tool rack, takes a probe from the magazine and immerse the probe into the liquid steel
in the tundish. Since the probe magazine contains probes for temperature- and hydrogen measurement as well as for sampling
(see Figure 7(a)), it had to be engineered “error proof” in order to make it impossible to exchange unintentionally the probe
type and therefore causing robot down times. After a positive evaluation of the measurement by the temperature
measurement system or after an elapsed maximum immersion time, the robot discards the probe in the probe bin. It turned
out to be a good operational practice, to cover the “open eye” in the meniscus of the tundish with one bag of tundish
insulation powder after each time a temperature measurement was taken. In order to keep the open eye small and to avoid
formation of scull in the tundish cover hole, it´s of advantage to cover the cardboard probe lances with an anti-splash coating.
Figure 7(b) shows a temperature measurement at CCM1.

Hydrogen measurement
From the procedure point of view, the hydrogen measurement is very similar to the temperature measurement except for the
different tool, probe type and immersion time, which is considerably longer compared to the temperature measurement.

1296 © 2019 by the Association for Iron & Steel Technology.

Sampling
Sampling is as well very similar to the temperature measurement except for the probe type and immersion time. After taking
the sample, the probe is discarded in the sample bin to hand it over to the operator for cooling and manipulating the sample
before sending it to the laboratory. Depending on the steel grade, up to three samples are taken during casting of one ladle at
defined ladle weights. Sampling- and measurement tasks are triggered automatically by the actual ladle weight (Auto Ladle
mode) to guarantee the precise timing of required measurement- or sample tasks. The list of tasks and their individual timings
were set for different steel grade families via HMI stored in the robot PLC.

(a) (b)

Figure 7. (a) Probe magazine containing different types of probes, (b) Temperature measurement in the tundish.

Powder application
Both robots carry out the task of insulation powder application simultaneously, whereas Robot 1 applies powder through the
left and the central hole and Robot 2 applies powder via the right hole of the tundish cover. The robots use a powder feeder
tool, which enables them to grab a staple of powder bags from the bays of the powder racks (see Figure 8 (a)). The adequate
type and amount of insulation powder bags have to be charged in the storage racks by the operator according operational
norms. Robot 1 is capable of transferring up to six powder bags at once, whereas Robot 2 can handle up to four powder bags
with one application. Figures 8(b) and 8(c) show the powder application to the left tundish cover hole of CCM1. During a
start of a casting sequence or after a tundish exchange, a lot of insulation powder has to be applied in a relatively short time.
Precise timing and fast delivery of the powder is crucial for preventing re-oxidation and keeping the steel temperature in the
tundish. To accomplish this task, the individual sub-tasks are triggered by the actual tundish weight (automatic sequence start
up function).

(a) (b) (c)

Figure 8. Powder application to the tundish of CCM1. (a) Powder rack filled with rice ash bags, (b) Bags transferred via the
powder feeder tool, (c) Powder application to the left tundish cover hole.

© 2019 by the Association for Iron & Steel Technology. 1297

This predefined practice ensures that the insulation powder is not applied too early during the tundish filling phase, since the
turbulent flow in the tundish would harm steel cleanliness of the first slabs. On the other hand, a too late application would
result in a compromised spreading of the powder at the tundish meniscus, since the surface velocities are relatively low after
the filling process is completed. The implemented practices also make sure that rice ash is only applied to the tundish after
the synthetic powder already has spread evenly at the meniscus. The automatic sequence start-up function is programed in
such a way that right after the application of insulation powder is done, the first temperature measurement is carried out to
inform the operator as soon as possible about the actual superheat.

In the second commissioning phase, the operational tasks, which required the use of the LTC mechanism, were implemented.
These tasks are as follows:

Ladle shroud handling

During casting, six monoblock ladle shrouds are available in the rack inside the robot cell. The rack is equipped with optical
sensors at each position for recognizing the presence of a ladle shroud. After grabbing a ladle shroud from the rack using the
pneumatically actuated gripper tool, the robot arm moves towards the LTC mechanism, which is already in casting position
with the ladle turret arm in the upper position. Mounting the ladle shroud requires the knowledge of the exact position in
space of the ladle shroud mechanism relative to the actual position of the ladle shroud (gripper tool). Since the ladle cannot
be positioned with the required precision by the ladle turret and the ladle itself is not manufactured within tight tolerances,
the position of the ladle shroud changer has to be determined (measured) each time before a ladle shroud is installed. The
exact position is detected using an optical measurement technique. The 3D-Laser measurement system mounted on the robot
arm measures the surface topography of a specially designed 3D-body, which is mounted on the LTC mechanism (see Figure
9(a)). The measured topography of the body gives the exact position and orientation of the ladle shroud mechanism relative
to the gripper tool. This methodology of determining the position of the ladle shroud mechanism is very robust against dust
and changes of illumination conditions. With the knowledge of the position of the LTC, the shroud is moved towards the
LTC and ready for shroud insertion. Charging of the monoblock ladle shroud requires only a vertical movement of the shroud
into the LTC, where it is fixed automatically by spring-loaded blocks. Figure 9(b) shows a ladle shroud installation.

(a) (b)

Figure 9. (a) 3D-Laser measurement system, (b) Robotized ladle shroud installation

After the robot has returned to its home position, the ladle is lowered, and the ladle opening is carried out with fully
submerged ladle shroud.
Before removing the monoblock ladle shroud, the precise position of the LTC mechanism is again determined via the laser
measurement technique. The ladle shroud is removed from the LTC by attaching the gripper tool to the shroud and released
from the gate by a 45° rotational movement. Finally, after arriving at the home position, the shroud can be inspected, cleaned
or discarded in the adequate bin.

Ladle shroud cleaning

Cleaning the ladle shroud after removing it from the LTC requires the combined operation of both robots. During this
operational task, Robot 1 is responsible for handling the ladle shroud and Robot 2 for handling the oxygen shower tool,
whereas the oxygen flow is controlled by the RCT - PLC. During cleaning, the ladle shroud is oriented towards the tundish in
order to minimize any safety- and operational risks due to liquid steel splashing (see Figure 10).

1298 © 2019 by the Association for Iron & Steel Technology.

 Figure 10. Ladle shroud cleaning using both robots.

Oxygen lancing
In case of a non-free ladle opening, operators may request the oxygen lancing functionality of the robot system. As already
mentioned before, due to the design of the LTC - ladle slide gate mechanism, the monoblock ladle shroud stays attached to
the LTC and therefore the time of open stream (and therefore the negative impact on the steel quality) is reduced to a
minimum after a successful opening of the ladle. After grabbing the ladle shroud lancing tool equipped with a telescopic
pipe, the robot positions the pipe tip right below the conical collector nozzle of the LTC. The operator has the possibility to
adjust the pipe position using a joystick, which is available in the operator cabin. During this adjustment (normally, only
small adjustments are necessary to centralize the pipe tip with the nozzle), the actual position of the pipe tip can be monitored
via a camera attached to the robot and a screen in the operator cabin. After positioning of the pipe tip, the operator triggers
the oxygen lancing procedure. The pipe itself is built as a telescopic pipe, whereas the oxygen pressure applies the force on
the plug inside the channel. After successful opening of the ladle, the robot moves the oxygen lance tool back to the rack and
soon afterwards, the tube change cylinder of the LTC mechanism charges the monoblock ladle shroud in cast position while
the ladle turret lowers the arm in casting position. An oxygen lancing operation is shown in Figure 11.

(a) (b)

Figure 11. Oxygen lancing operation. (a) Oxygen lancing pipe rack with lancing tools, (b) Oxygen lancing procedure.

© 2019 by the Association for Iron & Steel Technology. 1299

 OPERATIONAL ASPECTS

Instead of being autonomous, the robot system is fully integrated into the caster automation system which is vital for
handling emergency situations and keeping track of the executed operations, measurement results as well as quantities of
consumables via Level 2 automation system and the Manufacturing Execution System (MES).
In the case of emergencies, which call for an immediate ladle turret- or tundish evacuation, the robot, which is executing a
task at this very moment, has to react adequately and quickly in order not to worsen the situation. The movement of the robot
to its home position has no delay since the “emergency signal” from the caster PLC is send directly to the robot PLC. Several
simulations were carried out during the engineering phase of this project to minimize the movement time. It turned out, that
in the case of probe handling during emergency evacuation it´s of advantage to decouple the tool from the robot and leaving
it behind before starting the escape movement. A decoupling of the tool when executing the other tasks didn’t result in a gain
of time. The time between receiving the emergency signal and arriving at the home position varies between 6 to 9 seconds. It
should be again pointed out, that due to the use of the LTC mechanism without the need of a stationary ladle shroud
manipulator, there is no physical connection between the ladle and the casting platform during casting operation, ensuring
free turret movement in case of emergency evacuation. In case of a turret emergency, in order to save time, the ladle turret is
not moved upwards and therefore the ladle shroud breaks during the turret rotation by a intended collision with the tundish
cover.

Until the start of this project, only two types of data regarding tundish operations were sent to the Level 2 system and the
MES, namely the result of the manual temperature- and hydrogen measurement. What was not registered so far (and
therefore without evidence) was the exact timing of the sampling task (time, ladle weight etc.), the quantity and type of
powder application and shroud handling operations. Since all tundish operations are registered in the robot PLC, it is
relatively easy to send this data to Level 2 and MES for further processing.
Introducing a robot system in continuous casting is not only a big technological step forward, it is somehow a radical change
in the daily working experience of the operators, which was a concern before starting this project. However, it turned out that
hands-on training in the workshop of Vesuvius Belgium before the implementation of the robot system in the steel plant was
very beneficial for all involved persons in this project to get used to this new technology. A very important factor for the
acceptance of the robot and its operation is the layout of the operator cabin and the HMI. The new air-conditioned and noise
preventing operator cabin is shown in Figure 12.

1 Ladle turret panel

2 Slag detection system
1 3 Communication system
1 4 4 General robot operation panel
5 Oxygen-lancing panel
6 Oxygen panel

4 5
2
6

Figure 12. Operator cabin with its operation panels

1300 © 2019 by the Association for Iron & Steel Technology.

The new cabin houses already existing operator panels of the ladle turret (1), slag detection system (2) and communication
system (3) as well as new panels including the general robot operation panel (4), the camera system with joystick for the
oxygen-lancing task (5) and the oxygen panel (6). The robot operation panel allows conventional button-controlled operation
for measurement and sample tasks, but all operational functions and their adjustments can be carried out as well via the HMI
using the 30” touch panel.

During the first weeks of operation at CCM1, RTC carried out 152 powder applications and took 192 temperature
measurements, 20 hydrogen measurements and 89 steel samples. As shown in Figures 13 (a) – (d), the robot system proved
during this period its high availability and performance (rate of successful executions) of its four different tasks, which
reached during the first weeks of continuous operation the requested availability and performance of 95%.
.

(a) (b)

(c) (d)

Figure 13. RTC performance during startup.

During the startup phase, it was observed that the different ladles showed a significant deviation in the position after lowering
to the casting position. These deviations are caused by differences in the positioning of the ladle at the turret and
unpreventable deformations of the ladle during its lifetime. Therefore, the trajectory of the powder application via the center
hole of the tundish cover had to be optimized in order to guaranty a safe clearance between the ladle, tundish cover and
powder tool during powder application. This stepwise optimization process reduced the performance of the powder
application at the beginning of the test period.
The performance of temperature- and hydrogen measurements as well as sampling, was reduced in the first weeks of
operation by a formation of a solid shell at the tundish meniscus as well as a formation of scull at the tundish cover holes due
to steel splashes. When the probe collided with scull or a solid shell during its immersion, the robot´s collision detection
functionality kicked in and aborted the task. The collision detection functionality, which is monitoring the torque of each
drive, prevented thereby damage to the robot and its probe tool.
The formation of a solid shell at the meniscus was counteracted by optimizing the amount of insulation powder as well as the
application of one bag of insulation powder or synthetic slag each time after a measurement or sample was taken. The steel
splashes causing the formation of scull at the tundish cover holes could be reduced significantly by applying an “anti splash”
coating to the different probes.

© 2019 by the Association for Iron & Steel Technology. 1301

The commissioning of the LTC mechanism was still ongoing during the elaboration of the present work. By the end of May
2019, already 8 of the 23 ladles were converted to the LTC mechanism and the first tests of ladle shroud handling, ladle
shroud cleaning and oxygen lancing were accomplished successfully.

CONCLUSIONS

Introducing a robot system in continuous casting was not only a substantial technological step forward, it was a radical
change in the daily working experience. The implementation of the robot system at the casting platform and the new ladle
side gate mechanism on both continuous casting machines at Ternium Brasil had a profound impact on the safety of the
operational personal, the process reliability, process tractability productivity and product quality.

REFERENCES

1. F. Wimmer et al.: “A Major Step Ahead in Caster Safety with Extensive Use of Robotics in Continuous Casting
Technology”, CCR’04, Linz, Austria.
2. M. Hirschmanner et al:”LiquiRob-Improved safety and systematic procedures on the casting floor using advanced
robotics”, 11th ECCC, Düsseldorf, Germany.
3. J. Meisel et al.: “Experience and Evolution: 10 Years of robotics in continuous casting technology”, 8th ECCC 2014,
Graz, Austria.

1302 © 2019 by the Association for Iron & Steel Technology.