How sensors reduce wastage and scrap in the steel industry Today's article looks at how a variety of sensors help to reduce wastage and scrap in the steel industry, which increases production and cuts costs; also,less waste equals better profits too. Linear sensors are used in the steel manufacturing industry to control the thickness of sheet metal, the thickness of other shapes and sizes of raw product and the operation of some machinery, and their reliability here is paramount to maintaining productivity and reducing scrap. Sensors used in steel plants have to be able to withstand high heat, sometimes up to 180°c, as well as vibrations and shocks from the machinery as it runs. Sensors that rely on contact are not suited to these applications, but Positek has a range of linear sensors designed specifically for these types of challenging environment that use contactless technology, eliminating the problems associated with sensor movement due to vibration. They are also able to operate at high temperatures, although it is often recommended that sensors used in the steel industry are housed in a protective casing and as far away as possible from heat sources to reduce the risk of damage from heat or knocks.Stainless steel is used to make these sensors, so it is very likely that a linear position sensor will end up being used at a facility where some of the key materials were first made. Stainless steel resists corrosion so exposure to steam and moisture, as is found in metal production, is not a problem. Waterproof sensors could be used where there is excessive moisture present, as a preventative measure against a short sensor life span. Ruggedness and reliability are incredibly important here, as replacing sensors means shutting down equipment outside of planned maintenance hours, thereby reducing productivity. Choosing a sensor that will remain operable and accurate for a long time is important, as replacing and checking sensors can be done less frequently than with unreliable ones.During the casting process, molten steel is fed through a series of rollers designed to keep the material at the right thickness; a specification determined by the customer, who may want raw steel in a certain size, thickness or shape for further processing. If sensors fail to operate properly at this crucial stage then the steel could be cast to the wrong specification, resulting in scrap metal that needs to be re-processed or recycled altogether. It is important that sensors and the steel output are checked regularly, and that there is a monitored system in place for checking sensor feedback and stopping production should that feedback fall outside the acceptable range. The correct sensor output during production varies for each shape and size, but will always be the same for a certain thickness, or a particular shape, so this constant can be used to check real-time sensor feedback against, quickly identifying if something is amiss. The sooner incorrect production can be stopped, the less wastage there will be; so sensor reliability here really is vital for an efficient quality control system to operate. Article published on: 28/02/2017 Article last updated on: 28/02/2017