Application of Atonm Magnetic Scale Readhead in Displacement Detection of Vertical Folding Pot Position in Steel Plant

Ⅰ. Project Background

In the steel production process, the tension leveler roll serves as the core equipment for plate straightening. The precise control of its lifting displacement directly affects the flatness and surface quality of finished plates. A large iron and steel enterprise encountered two major challenges during the upgrading and transformation of its hot rolling workshop:

The original mechanical limit switches frequently gave false alarms in environments with high temperatures (50-60℃), strong vibrations (10-20Hz), and oil contamination, resulting in a downtime rate as high as 15%.

The process required the detection accuracy of the 60mm lifting stroke of the tension leveler roll to reach ±0.01mm. However, the traditional grating scale was prone to contamination by metal dust, leading to high maintenance costs.

Ⅱ. Technical Requirements and Pain Point Analysis

Extreme Environment Adaptability

The tension leveler roll area is long-term exposed to high-temperature radiation from hot-rolled strips, emulsion splashing, and equipment vibration. The glass gratings of traditional optical sensors are susceptible to contamination and thermal deformation. In contrast, the magnetic scale needs to pass the IP67 protection certification and the wide-temperature operation test ranging from -10℃ to 60℃.

High-Precision Real-Time Feedback

The tension leveler control system requires a displacement signal refresh rate of ≥1kHz and a resolution of 1μm. Meanwhile, it needs to be compatible with the SSI interface protocol of the existing PLC to ensure seamless connection with the AGC (Automatic Gauge Control) system.

Ⅲ. Atom Magnetic Scale Solution

Core Configuration:

Readhead: Atonm MH0-H200D Magnetic Scale Readhead (zinc-aluminum alloy housing, IP67 protection)

Magnetic Scale: Imported Magnetic Scale

Ⅳ. Application Effects and Customer Value

Performance Improvement Data

Accuracy: The displacement measurement error has been reduced from ±0.08mm (of the original system) to ±0.008mm.

Stability: The equipment failure rate has decreased by 92%, and the annual maintenance cost has dropped from RMB 850,000 to RMB 62,000.

Response Speed: The displacement signal delay has been shortened from 50ms to 8ms, meeting the dynamic control requirements of high-speed rolling (180m/min).

Customer Evaluation

"The Atonm magnetic scale system has demonstrated excellent reliability in the actual operation of the hot rolling workshop. Its maintenance-free feature and anti-interference capability have completely solved the long-standing equipment downtime problem that troubled us."

— Head of the Equipment Department of the Iron and Steel Enterprise

Ⅴ. Industry Promotion Value

This solution breaks through the application bottlenecks of traditional displacement detection technology in high-temperature and strong-vibration environments, providing a new paradigm for precision displacement control in industries such as metallurgy and forging. The successful application of the Atonm MH0-H200D magnetic scale system offers an ideal solution for multi-axis collaborative control in intelligent manufacturing scenarios.