Alternative routes in steel production: wire steel, forgings and castings 

In addition to sheet metal production via hot and cold rolling lines, there are several alternative routes, each with its own process characteristics and sensor needs. Although the basic principles of material movement and temperature control are common, the application varies greatly by product type. 

Wire steel - wire rolling line 

In the production of wire steel, such as rebar, the steel is formed into long, thin wires rather than wide sheets. This is done via a wire rolling line with multiple rolls and often high speeds. 

Why IoT sensors for wire steel at a wire rolling line? 

1. Infrared temperature sensors: to ensure proper deformation temperature and avoid material stresses. 
2. Ampere/consumption sensors: to detect wear or overload of the drives early. 
3. Vibration sensors: to detect imbalance in coils that may affect wire quality. 

Forging products - forging line 

In forging, slabs from the continuous casting process are formed under high pressure with hammers or molds. This is a force-intensive process involving temperature and mechanical stress. 

Why IoT sensors for forging products? 

1. Infrared temperature sensors: to keep the forging material at the right temperature for optimum formability. 
2. Pressure sensors: to monitor the operation of hydraulic systems and forging presses. 
3. Ampere/consumption sensors: for monitoring drives and press motors, essential for process safety and maintenance. 

Molded products - direct mold casting 

Instead of continuous casting into semi-finished products, the molten steel is poured directly into a final form, as in sand casting. This is used for complex shapes such as flywheels. 

Why IoT sensors in mold casting? 

1. Infrared temperature sensors: to monitor the melting temperature of the steel and ensure consistent casting quality. 
2. Pressure/vacuum sensors: for monitoring gas flows and filters in the casting plant. 
3. Differential pressure sensors: for monitoring exhaust filters to prevent clogs or leaks.