The steel industry remains an indispensable part of the economy of many countries, including China and the United States. Modern steel plants must operate extremely precisely in order to produce consistent, high quality output. Reliable wireless communication and tracking systems are key components of steel production operations to reduce maintenance workload, increase efficiency, and reduce the risk of accidents. For example, the ladle transfer cars that transport molten steel have the potential to cause serious accidents, such as breakouts, which can lead to production interruptions, injuries, and even loss of life. Proper wireless monitoring and control of the ladle transfer cars would mitigate these risks.

 

• Save cable maintenance cost
• Prevent data loss to maintain quality of production
• Provide wireless roaming for seamless handover
• Widely distributed network with seamless connectivity
• Up to 15 Mbps for stable throughput
• Level 3 EMS (Electro-Magnetic Susceptibility)

 

For this system, a reliable wireless remote control system can be used to telemetrically connect ladle transfer cars to a central control center. This wireless communication system can maintain real-time data access without compromising car mobility. AWK-5222 units are placed every 100 m to form bridge networks along the car tracks in order to create wireless network coverage across the entire plant. Thanks to dual RF channels, the AWK-5222 can easily create redundant two-way cascade links and form a bridge network by running the same device in both master and slave mode. This optimizes the reliability and cost-effectiveness of each wireless unit while maintaining a throughput of up to 25 Mbps. The AWK-5222 nearest the control room links the wireless backbone to Ethernet via an unmanaged EDS-208A switch.

AWK-6222 units are installed as redundant clients in the ladle transfer cars and connect to PLCs that remotely control and monitor a number of factors, including car location, environmental conditions, and furnace operating conditions. To connect the ladle transfer cars to the wireless backbone, the AWK-6222 units are configured as redundant APs and are linked to AWK-5222 units using an Ethernet cable. The two independent RF modules form a redundant wireless connection between the AP and client to ensure no data loss and safe operations. Fast roaming between APs ensures uninterrupted
performance across the entire wireless coverage area.

A steel plant is a harsh operating environment that includes dust, smoke, vibration, EMI/noise, and extremely high temperatures. The AWK-6222 overcomes these hazards with an IP68 rating, -40 to 75 °C operating
temperature range, and level 3 EMS rating.