بازطراحی خط اره جهان فولاد غرب؛ سنکرون‌سازی ۱۳ موتور و ارتقای ایمنی

The control systems and electrical panels of the sawing section at Jahan Foulad Gharb’s production line were refurbished and upgraded as part of a technical project. The project included equipment and cable replacement, redesign of the control systems, synchronization of 13 rollgang motors, and implementation of preventive protection systems, with the aim of improving safety, reducing downtime, and enhancing production-line reliability.

The project began with a detailed assessment of the existing electrical panels. Equipment deterioration, damaged wiring, the lack of up-to-date drawings, and the aging of some protective devices were among the main issues identified at this stage. To address these challenges, current paths and the operation of existing components, including contactors and relays, were examined, and the initial system diagram was extracted and documented.

The new system was then designed to improve control accuracy and safety. The electrical drawings of the panels were redesigned using EPLAN software. Worn-out equipment was also replaced with new components, and following approval of the drawings, the physical refurbishment of the panels and installation of new wiring were carried out.

One of the key components of the project was the synchronization of 13 rollgang motors. By making the necessary adjustments to the inverters, the motors’ synchronized movement was improved to prevent roller wear caused by continuous contact with the steel beams. Brake resistors were also designed and installed.

As part of the safety improvements, control fuses were installed for the panels, and an emergency system was provided for all panels. In addition, five new panels were designed and installed for the saws’ hydraulic system and the operator room. Indicator lights were also installed to enable faster fault identification and facilitate troubleshooting.

The renewal of the cabling network was another component of the project. Old and deteriorated cables inside the cable trenches were removed and replaced with new ones. In addition, by optimizing the location of the electrical panels, communication routes were shortened and the number of cables required was significantly reduced.

Alongside the equipment upgrades, the saws’ protection systems were also enhanced. One of these protection systems was activated to prevent saw blade breakage. When the saw moves forward to cut a steel beam, if the beam-transfer rollers do not move, the saw’s forward movement is automatically stopped. This protection helps prevent conditions that could damage or break the blade, even in the event of an incorrect command from the operator.

Another protection system was activated to prevent the saw from becoming jammed along its travel path. If such a condition occurs, an audible warning is issued first. Subsequently, the final rack is shut down to prevent the steel beam from continuing to move and colliding with the saw blade.

In addition, automating Bed Chain No. 1 has accelerated the collection of cut steel beams. Overall, these measures have resulted in reduced downtime associated with the saw electrical panels and lower maintenance and repair costs.

Another outcome of the project was the localization of electrical drawing and panel design, along with the preparation of standardized system drawings. Specific identification codes were also assigned to all communication cables, making it easier to trace cable routes and carry out maintenance and troubleshooting operations.

Overall, this project was more than a simple equipment refurbishment. By simultaneously focusing on modernization, safety, control, protection, and downtime reduction, it localized and upgraded the electrical and control systems of the sawing section at Jahan Foulad Gharb’s production line.