Bar mill and wire rod mill optimization: profile rolling process goes digital

Harness high level plant and process data and use it to trace and visualize the KPI’s important to your profile rolling mill, right down to individual billet precision. Detect and analyze deviations, identify their root cause and use the insights gained to predict and prevent faults before they affect production.

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  • Do you know all of the specific mill parameters that contribute to productivity, quality and yield at your long product rolling mill?

  • How many automated control point solutions are leaving you with disconnected data, people and processes?

Manual monitoring is unrealistic due to the large number of data sources and process variables. Operators need more advanced tools to help them better understand the trends and inter-relations between the process parameters that cause faults and failures.

New technologies are increasingly used for this purpose, but success in digital depends on the availability of process expertise in both implementation, operation and maintenance of these tools. 

At ABB we believe that a more collaborative approach is the way forward to  benchmark and troubleshoot processes, to identify and counteract root causes more rapidly - improving yield and quality, productivity and margin across the value chain.

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Digital solution tailored to profile rolling process

ABB Ability™ Data Analytics for long product rolling mills is the core digital technology that seamlessly integrates automation technologies for metals, provides data connectivity and storage, customizable dashboards, as well as analytics engine specific to profile rolling. It is available as a service or as a stand-alone product.

As part of  Performance Optimization Service for long product rolling mills  this solution also includes continuous monitoring,  real-time expert support and system maintenance delivered remotely via the ABB Ability™ Collaborative Operations for metals platform.




Intuitive dashboards

Secure, reliable data storage at customer site, real-time visualization of KPIs on both plant and billet level for any time duration/campaign with the ability to check any raw signals/trends from the IBA data for individual billets.

Powerful analytics engine

Process-specific tracking and performance optimization modules with breakdown prediction and comparing current operating conditions with agreed benchmarks.

Real-time monitoring & remote support

Continuous, real-time monitoring and expert support via ABB’s Collaborative Operations Centers include proactive deviation alerts, reports, system maintenance and updates

Key process health indicators

Combining data analytics, process-specific algorithms, real-time continuous monitoring and remote support  into one powerful performance optimization service lets reveal the trends and inter-relations between various process parameters at your mill. Examples of key process health indicators include:

  • R factor variation
  • looper and tension profile
  • pinch roll performance (slippage)
  • shear cut cycle repeatability
  • mill pacing team
  • motor speed and torque profile

ABB experts allow you to access a much higher level of process insights, apply them to achieve and maintain optimal operations - enabling faster, more data-driven decisions. The resulting insights can even be leveraged across multiple sites to unlock further cost savings at enterprise level.
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Use case examples

Flexible architecture with option to run on Cloud or on premise

  • You, the customer, own your data which is stored onsite at your premises
  • ABB and your designated staff have 24/7 online access to intuitive dashboards
  • ABB remotely monitors dashboards and process KPI's to alert to and advise you on process discrepancies
  • This technology seamlessly integrates with ABB's data analytics platform and automation technologies for metals

Partner with ABB to accelerate your digital transformation journey

Getting to the stage where a plant can gain maximum results from digitalization demands planning a business relevant and executable path
Digital transformation in steel industry
Why ABB?
  • Experienced provider OT and IT stack
  • Third party and legacy integration
  • Domain knowledge and metals industry knowledge
  • Efficient transformation projects, focus on ROI
  • New tools such as cloud, analytics
  • Development model with partners to jointly develop solutions

>> ABB references in metals industry

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