Process Monitoring
Automated real time monitoring of processes, machines and plants is based on acquired measurement data, camera images and calculated characteristic…
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Steel
Sectors
Steel production is characterized by sequential process steps with stringent quality requirements. The quality of the final product depends directly on physical and chemical parameters. In particular, precise temperature control during heating and cooling processes is highly demanding and requires continuous monitoring. In addition, the extremely fast operations in rolling mills are especially critical and have a major impact on product quality. With the iba system, steel plants and rolling mills gain complete transparency across all process steps, including critical parameters and process variables.
Data as a Strategic Competitive Advantage
Only complete transparency enables informed decision-making in demanding production environments.
The iba system acquires all relevant process and machine data synchronously, at high sampling rates and high resolution, visualizes them clearly, and delivers valuable insights across the entire metallurgical value chain. Processes such as rolling, heating, cooling, and forming can be fully captured and monitored to ensure consistently high product quality – even under the harshest operating conditions. In addition, the data can be used for predictive maintenance to detect wear, faults, and anomalies at an early stage and avoid unplanned downtime.
This enables detailed root-cause analysis, early fault detection, continuous process optimization, and data-driven decision-making – ensuring maximum productivity and stable product quality under all conditions.
The iba system provides us with robust and reliable data acquisition. Exactly what we need for our demanding processes.
Mohamed Bousnane
Process Engineer, LSV Lech-Stahl Veredelung GmbH
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Successful applications and real solutions with the iba system.
Vibration Analysis
For reliable real-time monitoring of vibrations, offline analysis tools for optimization and validation are indispensable. The iba system offers you…
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Quality Control
For documenting the automatically manufactured products, quality data and characteristic values need to be calculated and reliably stored in a quality…
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Process Analysis With ibaCapture: Keep an Eye on the Entire Plant With Process Specific Camera Monitoring
Usually, the operator does not have a free view on all components and aggregates from the control panel of a rolling mill. This is why camera systems…
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Unlocking the Full Potential of Measurement Data: A Value Creation Approach Through Digitalization
Increasing complexity and process speed pose significant challenges for technology-intensive manufacturing companies. Not only do these factors make…
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Long-Term Analysis
The iba system enables continuous acquisition and long-term storage of process and machine data in high temporal resolution. All data is centrally…
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PLC Analysis
Failures in automated systems can lead to production downtime and inferior quality. Failure mode analysis is easily achieved for maintenance personnel…
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Increasing Product Quality by Means of Visual Signals: Online Process Monitoring With ibaVision
The task is to detect rhomboidity during a continuous casting process. This needs to be done to allow timely process adjustments and consequently…
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Digital Process Optimization at thyssenkrupp Electrical Steel
At the cold rolling mill of thyssenkrupp Electrical Steel (tkES) in Gelsenkirchen, the team faced a familiar yet complex challenge.
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AI-Powered Coil Strap Detection with ibaVision
In the production of aluminum coils, proper strapping is essential to ensure safe handling and transport.
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Digital Process Optimization in Steel Refining at LSV
The heat and surface treatment of steel is a complex and sensitive technical process. With the iba system, LSV implemented a comprehensive solution…
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Finding a Needle in a Haystack in Seconds: BILSTEIN Monitors Coils With ibaDatawyzer-ICC
Over 1,600 tons of metal, rolled into coils, pass through the BILSTEIN Group’s production facilities every day. To eliminate the risk of mix-ups, the…
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“With ibaHD-Server, we have direct access to seven years of historical data”
What began seven years ago with the replacement of paper chart recorders in a pusher-type furnace has evolved into a key pillar of quality assurance…
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“ibaDaVIS gives all users easy access to the data and helps us resolve emerging issues more quickly.”
As the legacy system no longer met operational demands, the BILSTEIN GROUP had to seek out a new solution for process data visualization. Their…
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Detect Causes of Faults Faster and Reduce Unplanned Downtime: Hirschvogel Group Increases Productivity With the iba System
The Hirschvogel Group, one of the largest, globally operating automotive suppliers in the field of massive forming of steel and aluminum, decided to…
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Determining the Optimum Time for Wear Replacement: Salzgitter Flachstahl Uses Condition Monitoring System for Early Detection
A complex mechanical plant was equipped with a condition monitoring system. In the first year after installation, some cases of wear damage were…
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Democratization of Data With ibaDaVIS: Data Acquisition and Visualization in a Rolling Mill With ibaPDA and ibaDaVIS
A strip steel producer based in Germany uses ibaDaVIS to overview and evaluate data over the long term. This allows problems that arise to be solved…
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Detecting Critical Vibrations in Rolling Mills
In a cold rolling mill, the process data recording system ibaPDA has been used for process data analysis, but the vibration measurement data was…
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Monitoring Gears the Intelligent Way: Preventing Plant Downtimes With Condition Monitoring as Early Warning System
Significant savings can be made with preventive maintenance using sensor-based Condition Monitoring. This is why Condition Monitoring gets more and…
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From Scrap Basket to Heat Analysis
How Badische Stahlwerke Uses the iba System to Bring Transparency to Scrap Charging
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Badische StahlwerkeCompanies That Rely on iba
These leading companies already rely on the iba system.
Frequently Asked Questions (FAQ)Continuous data acquisition provides the foundation for transparent and stable production processes in the steel industry. The iba system captures process and machine data synchronously and at high resolution across all production stages—from heating and rolling to cooling. This enables early detection of quality deviations, complete process traceability, and data-driven production decisions based on reliable information.
In steel production, even minor deviations in temperature, rolling force, or material handling can significantly impact product quality. The iba system records these process variables at high temporal resolution and makes them available for visualization and analysis. This allows critical operating conditions to be monitored reliably, quality issues to be identified more quickly, and production processes to be continuously optimized.
Long-term process data enables comprehensive technological analyses and comparison of production batches over extended periods. With the iba system, historical measurement data can be archived and analyzed in detail using ibaAnalyzer. This supports root cause analysis, improves process stability, and provides valuable insights for continuous process improvement.
Continuous monitoring of machine and process data forms the basis for predictive maintenance. The iba system detects wear, anomalies, and process deviations at an early stage and provides this information to maintenance teams. This helps reduce unplanned downtime, enables targeted maintenance planning, and improves overall equipment availability.
When process data is made centrally available, production, quality assurance, maintenance, and process engineering teams can work from the same information base. The iba system provides web-based visualization of measurement data and makes it accessible across departments and locations. This accelerates decision-making, improves collaboration between teams, and helps identify optimization opportunities more efficiently.
Continuous data acquisition provides the foundation for transparent and stable production processes in the steel industry. The iba system captures process and machine data synchronously and at high resolution across all production stages—from heating and rolling to cooling. This enables early detection of quality deviations, complete process traceability, and data-driven production decisions based on reliable information.
In steel production, even minor deviations in temperature, rolling force, or material handling can significantly impact product quality. The iba system records these process variables at high temporal resolution and makes them available for visualization and analysis. This allows critical operating conditions to be monitored reliably, quality issues to be identified more quickly, and production processes to be continuously optimized.
Long-term process data enables comprehensive technological analyses and comparison of production batches over extended periods. With the iba system, historical measurement data can be archived and analyzed in detail using ibaAnalyzer. This supports root cause analysis, improves process stability, and provides valuable insights for continuous process improvement.
Continuous monitoring of machine and process data forms the basis for predictive maintenance. The iba system detects wear, anomalies, and process deviations at an early stage and provides this information to maintenance teams. This helps reduce unplanned downtime, enables targeted maintenance planning, and improves overall equipment availability.
When process data is made centrally available, production, quality assurance, maintenance, and process engineering teams can work from the same information base. The iba system provides web-based visualization of measurement data and makes it accessible across departments and locations. This accelerates decision-making, improves collaboration between teams, and helps identify optimization opportunities more efficiently.
