You are on page 1of 38

2013-2014

Lancelot
Introducing Location Tracking of Oxygen Lances in Steel Production

Evan Baumis, Taylor Reynolds


[ ARCELOR MITTAL ]

TABLE OF CONTENTS
TABLE OF CONTENTS ............................................................................................................. 1 EXECUTIVE SUMMARY .......................................................................................................... 3 SECTION 1: PROJECT BACKGROUND AND HISTORY ................................................... 4 1.1 STATEMENT OF PROBLEM ................................................................................................... 4

1.2 PREVIOUS SOLUTIONS ............................................................................................................. 4 1.3 SCOPE OF WORK ..................................................................................................................... 5 1.4 TEAM CHARTER ...................................................................................................................... 8 SECTION 2: CONCEPTUAL DEVELOPMENT STAGE .................................................... 10 2.1 REQUIREMENTS MATRIX ...................................................................................................... 10 2.2 FUNCTIONAL DECOMPOSITION ............................................................................................. 12 2.3 CONCEPTUAL DESIGN PLAN ................................................................................................. 14 2.3.1 Results of Research ...................................................................................................... 14 2.3.2 Construction Models .................................................................................................... 15 2.3.3 Experimentation and Testing....................................................................................... 15 2.3.4 Three Conceptual Designs ........................................................................................... 16 2.3.5 Down Selection Process ............................................................................................... 21 2.3.6 Final Design Selection ................................................................................................. 22 2.3.7 Preliminary Budget ...................................................................................................... 22 SECTION 3: PROCESS/PROJECT DESIGN STAGE .......................................................... 24 SECTION 4: PROJECT FABRICATION STAGE................................................................. 25 SECTION 5: PROJECT TESTING AND EVALUATION STAGE ..................................... 26 SECTION 6: PROJECT MANAGEMENT INCLUDING SCHEDULES ............................ 27 6.1 WORK BREAKDOWN STRUCTURE AND SCHEDULE FOR CONCEPTUAL DESIGN PHASE .......... 27 APPENDICES ............................................................................................................................. 31 TEAM MEETINGS DETAILS ......................................................................................................... 31

TRIP REPORTS............................................................................................................................. 32 Arcelor Mittal 9/24/13 ........................................................................................................... 32 Arcelor Mittal 10/22/13 ......................................................................................................... 34 REFERENCE MATERIAL............................................................................................................... 36 TABLE OF FIGURES ..................................................................................................................... 37

EXECUTIVE SUMMARY
Arcelor Mittal is in need of a way to wirelessly track oxygen lances for the fabrication of steel. The oxygen lance is the key ingredient to the integrated process of steel production. They are lowered down into a BOF (Basic Oxygen Furnace) vessel, where a high percentage of pure oxygen is blown into the liquefied pig iron, for a preprogrammed amount of time. The purpose is to lower the carbon content of the iron. One complete cycle is termed as a heat. The operators need to know which oxygen lance has been used where, and for how long. This leads to quality problems and equipment damage if heats on a lance are not tracked properly, or if the operator thinks he has a certain lance and a different one is in it. The objective of this project is to implement a wireless tracking system that will transmit bidirectional data, store the received information into memory, and link it to a Wonderware screen, where an operator will monitor it. A wireless system utilizes communication between a reader and a transponder. The transponders will incorporate a coil antenna, a microchip, and the ability to read and write to memory. A different transponder tag will need to be attached to each oxygen lance. Readers will need to be placed near both BOF vessels, and power the transponders remotely when they are in range. The system will be interfaced with the Controllogix PLC (Rockwell Automation, 2013), and configured for the Wonderware lance tracking software. Testing of the various components within the project will prove to be challenging due to the fact that it will be difficult to replicate the environment the application will operate in. Therefore we will closely imitate operating conditions. RFID tags (Finkenzeller, 2010) will be tested by exposing tags to temperatures up to 130F along with RFID transponders. In order to test communication between the RFID transponder and PLC, a card will be utilized that imitates the PLC system at Arcelor Mittal. We will bring a sensor within range and observe the output on the PLC. We will also create a Wonderware screen to display the appropriate details of each tag (lance).

SECTION 1: PROJECT BACKGROUND AND HISTORY


1.1 STATEMENT OF PROBLEM

Our team is taking part in this project in order to improve Arcelor Mittals efficiency. Arcelor Mittal is unable to accurately manually track oxygen lances due to the environment. Our main goal is to successfully introduce a system that allows the company to decrease transition times between heats by better relaying information pertaining to oxygen lance positions. Currently, standby lances are activated and sometimes lances are used when they are in need of maintenance. This system will communicate accurate information to operator allowing for better efficiency. A successful solution will be introduced to other tools such as Arcelor Mittals ladles. Also, there is potential of increasing the output of steel. An increase of product introduces opportunities on a broad spectrum. Across America, there is a demand for jobs. The slightest improvement in a companys output allows that company to make jobs available. This increase of output demands the steel to be transported to a job site. At this job site the steel will be crafted for the specific application. Both scenarios pay working men and women. In sum, a tracking system for an oxygen lance plays a small role in a big picture. However, it does its part in improving a company, which works towards the goal of a better tomorrow.

1.2 PREVIOUS SOLUTIONS

Currently, Arcelor Mittal is using an extremely basic tracking system. As lances are transferred from the various positions, a worker is designated to record the condition of the lances. This person then radios down to the operator, relaying which lance is active, cooling down, or in standby. This current system allows for a downtime of 25 minutes minimum. In this time lances are relocated, and observers record lance information of 15 positions maximum (nine holding rack and three for each BOF). Some lances are taken from the holding rack and moved to a BOFs north or south position. This can be a very faulty system because there is always the likelihood of human error. Each lance has a number painted near the top located near the oxygen
4

and water valves. The observer needs to find the number through the dimly lit working space which is clouded with an immense amount of dust. This could cause the observer to inaccurately record which lance position is active. The operator then would initiate the lance position that is in standby. This wastes resources and causes unnecessary chaos. In an event such as this additional downtime will be added in order to switch the active and standby positions. Arcelor Mittal has previously seen the need for a more efficient tracking system but have never attempted one. In searching of existing patents, it was determined no other solutions have been documented.

1.3 SCOPE OF WORK

The scope of work for this project is to design, simulate, and test a system, to wirelessly track oxygen lances for use in steel production. The employees at Arcelor Mittal need to know where in respect to each furnace a lance is, how many cycles a lance has been through, and where a lance is in respect to other lances in the holding bay. Not knowing where current lance position is leads to quality problems and equipment damage if heats on a lance are not tracked properly, or if the employee thinks he/she has a certain lance and a different one is in it. The system needs to identify which oxygen lance and which Basic Oxygen Furnace (BOF) is active. The system also needs to identify which oxygen lance is in the standby position, and which position the lance is in relative to the active lance as shown in Figure 1 (North or South location). Additional oxygen lances that are added, or already stationed on the holding rack shown in Figure 2, will also be identified. Information about the oxygen lance needs to be displayed and automatically updated to the operators monitor screens.

Figure 1 Positions above BOF (North, active, South respectively)

Figure 2 Holding rack in bay with multiple oxygen lances The system will incorporate a manual override so that the lance information can be edited manually, without being automatically overwritten. A PLC will serve as the interface between the wireless sensors and the operators human machine interface (HMI).
6

A different RFID tag or barcode needs to be attached to each oxygen lance. The RFID tags or barcodes need to be attached to an oxygen lance, which is cylindrically shaped, and survive 130F continuously. The readers need to be placed near both BOF vessels, as well as the wall rack. The readers have to power the RFID tag remotely within 8 feet. Success will be determined by the tracking system accurately locating each oxygen lance within the operating space shown in Figure 3. The system can be broken down into three functional operating areas: hardware, ability to interface, and software. The hardware consists of the field devices, such as the tags and the readers. The system must interface with an Ethernet switch, connected to a Controllogix PLC, running Wonderware software. The Wonderware software serves as the HMI, allowing information to be sent to and from the operators. A successful project will meet a runoff period of (TBD).

Figure 3 Area of Operation The Controllogix PLC is a constraint that will require a function to be developed in order to receive, interpret, and store the data from the RFID or barcode transponders. The information will be transmitted through a RadioLinx (JPrat, 2009) wireless Ethernet switch, which is already compatible with Controllogix PLC. Another constraint is the Wonderware HMI, as it will require the software to be configured to work with a RFID or barcode solution to display the new information to a user interactive window. A tested, working prototype of this system will be ready in April of 2014. The system design, construction, and hardware testing will be performed at Purdue University, while the
7

software testing will take place in the field. Arcelor Mittal will provide the financial support, as well as installation of the finalized system. Dr. Dunlap and Dr. Leon-Salas will provide guidance during the course of the project.

1.4 TEAM CHARTER

The members of Team Lancelot are Taylor Reynolds, the document and schedule keeper, and Evan Baumis, the spokesperson. The role of document keeper is to maintain all project related documents in an organized, yet accessible way. The schedule keeper keeps the team on track, creating weekly goals, and checkpoints along the way. The role of the spokesperson is to be the main contact of the group, and regulate communications between Team Lancelot, Professor Sanger, the project engineer, and both faculty mentors. Both team members are expected to attend all meetings, lectures, and labs. Each member should show up on time, with all preliminary assignments completed, and any relevant resources brought along with. The outside work should be shared, with both members contributing equally. Both team members should be committed to taking the time to perform all necessary tasks. Each member should check his email inbox once per day, and his phone once per hour. Any cancellations of meetings should be communicated to the group member prior to the scheduled time. The role of both members will be shared, however the project may be broken down into blocks with each member responsible for his block. Both team members have taken an electronic communications course, and are concurrently in an electromagnetics course, which should prove to be an asset. Both group members are familiar with Dr. Leon-Salas and Dr. Dunlap, which is another asset. Evan is skilled in embedded digital systems, and digital signal processing. Taylor is particularly good at analog systems, and modulation techniques. Both faculty mentors are expected to keep the team understand researched information, and offer suggestions if the progress slows down when it shouldnt. If a mentor notices that the Team Lancelot is steering off track, he is expected to help redirect the solution.

Signature of Team Member: ___________________________ Date: ________________

Signature of Team Member: ___________________________ Date: ________________

Signature of Faculty Mentor: ___________________________ Date: ________________

Signature of Faculty Mentor: ___________________________ Date: ________________

SECTION 2: CONCEPTUAL DEVELOPMENT STAGE


2.1 REQUIREMENTS MATRIX

Table 1 Requirements Req # 1 Requirement Description The sensor tags must survive a temperature of 130 F for continuously The readers shall be mounted to the wall via (TBD) Tag shall be mounted via (TBD) The transponder will be powered by (TBD) Test Requirement Type Functional

Temperature

Analysis

Transponder Mount

Demonstration

Interface

Tag Mount

Demonstration

Interface

Power Source

Analysis

Performance

The readers must Communication communicate wirelessly to the RadioLinx The data shall be displayed in a separate window of the Wonderware software The system shall display data and send commancds via Wonderware software System must interface with Controllogix PLC

Demonstration

Interface

Display

Demonstration

Functional

Data Collection

Demonstration

Functional

System Interface

Demonstration

Functional

10

Lance ID

Data must correctly display lance ID Data must display number of heats lance has been through System must display lance location accurately in relation to other lances The system must be able to communicate to devices a max of 25ft away The system's memory will be no more than (TBD) bytes System must be able to accommodate additional tags

Demonstration

Interface

10

Usage Record

Demonstration

Interface

11

Lance Location

Demonstration

Performance

12

Range

Demonstration

Performance

13

Memory

Analysis

Interface

14

Replication

Demonstration

Interface

15

Cost Manual Override

16

18

Update

Budget is limited to Analysis $10,000 max System must allow operator to set lance position Demonstration without automatic overwrite The System must automatically update the Demonstration status of each lance every second

Functional

Interface

Functinoal

11

2.2 FUNCTIONAL DECOMPOSITION

A brainstorming session was held during the group meeting on September 9th. A brain writing technique was used, where both group members generated ideas individually, shared them with each other, and then expanded on them. A list of ideas was generated and crossreferenced with research from The RFID Handbook: 3rd Edition. The possible wireless tracking solutions were categorized into a decision table, to direct the functionality of the system, and what aspects are needed. Table 2 Various aspects of systems and options Category Operation Type Data Quantity Programmable Data Carrier's Operating Principle Sequence Power Supply Frequency Range Data Transfer from Transponder to Reader Response Frequency FDX 1 bit EAS Yes IC State Machine Battery LF Sub Harmonics 1 Implementation Options SEQ >1 Bit No SAW Microprocessor Passive RF Back Scatter 1/n-fold HDX

UHF Load Modulation

Microwaves

Using the decision table, along with brainstormed ideas, a concept table was formulated where the possible solutions were broken down into finer detail.

12

Table 3 Concept Selection Transponder Power Memory Operation Half Duplex Full Duplex Sequential Range Reader Frequency

Passive Battery RX/TX

EEPROM FRAM SRAM Read Only

Close Coupled System Remote Coupled System Long Range System

RS-232

LF

Ethernet HF WLAN UHF Microwave

The possible Solutions were analyzed based on their strengths, weaknesses, and their fulfillment of the requirements. A preliminary strengths and weaknesses table (Table 4) was created to make comparisons between several competing methods. The counterpart to each method, have opposite strengths and weaknesses. For example, a passive system has a lower transponder cost with a higher reader cost, while an active system has a higher transponder cost with a lower reader cost. Table 4 Preliminary Strengths and Weaknesses Method Passive Strengths Lower Transponder Cost Longer Transponder Lifetime Lower Transponder Cost Small Amount of Data Required Low Power Consumption High Transmission Range Higher Transmission Range High Memory Capacity High Temperature Range Robust Against EMI Fields Low Power Consumption High S/N Ratio Read/Write Capable Complex Sequences Weaknesses Higher Reader Cost Lower Transmission Range More Suceptable to EMI Fields Unidirectional Data is stored in Computer Database

Read Only

Microwaves

More Complex Design Requires a Backup Battery

Sequential State Machine

Auxillary Capacitors Needed Slower Transmission Rate Chip Maintenance Not Flexible

13

The most viable approaches were selected according to the criterion specified in section 2.3.5 and seen below.

Operating Temperature of reader Operating Temperature of Tag (degree F) Range of the system (ft) Vulnerability to collision (1 = low and 4 = high) Price of system (estimated) Frequency of maintenance (per month) Number of Readers needed (per BOF) Number of Tags needed (per Lance)

2.3 CONCEPTUAL DESIGN PLAN

2.3.1 RESULTS OF RESEARCH

Table 5 Specifications of various components Operation Type Data Quantity Programmable Data Carrier's Operating Principle Sequence Power Supply Frequency Range Data Transfer from Transponder to Reader Response Frequency FDX 1 bit EAS Yes IC SEQ >1 Bit No SAW

State Machine Microprocessor Battery Passive LF RF Sub Back Scatter Harmonics 1 1/n-fold

UHF Load Modulation

Microwaves

14

Through research it was learned it would be difficult to use RFID. If multiple tags are within range of a single reader signals become complex. A system is required to be developed in order to show relative position.

2.3.2 CONSTRUCTION MODELS

2.3.3 EXPERIMENTATION AND TESTING

Figure 4 Concepts and Respective Solutions

15

2.3.4 THREE CONCEPTUAL DESIGNS

Figure 5 Three Conceptual Designs Diagram

1) RFID system with a received signal strength indicator Uses UHF range (915MHz). o Most reliable high frequency range around water. The RSSI readers measure the relative power level coming from each transponder. o Reflections and absorptions in the environment may reduce the accuracy of the measurement. (Hansen & Oristaglio, 2000) A more difficult PLC function will be required to determine the distance. o The distance from the tags to the scanner is approximate. o The location may be incorrect if two RFID tags are within 1ft. of each other. Place 1 stationary RFID scanner at each BOF and at the wall rack. o Requires only 3 RFID scanners, however they are more than $3000 each. Each RFID scanner should be placed in front of the right most lance position of each area, facing back towards the remaining possible lance positions. No two RFID tags should be the same distance to the scanner. 3 high temperature RFID tags mounted to the top of each oxygen lance.

16

Figure 6 RFID Tag

2) Barcode system Applying multiple high temperature adhesive barcode tags completely around the lance. Positioning a stationary barcode scanner at every possible lance position no more than 1ft. away. o Requires 15 barcode scanners, but they are less than $1000 each. o Requires a direct line of sight between the barcode tags and the scanners. Each barcode scanner represents a specific location. o This will make it easier for the PLC to distinguish the lance positions.

Figure 7 Simple Mountable Barcode Scanner

Figure 8 2D Barcode
17

3) RFID system with an attenuated range Uses UHF range (915MHz) or Microwaves (2.4GHz). Place 2 stationary RFID scanners at each BOF. o Required Each scanner will be placed in front of the right most and left most lance position of each area, facing towards the middle lance position. o Position of the RFID scanners is key to the operation of this system The scanner ranges will be attenuated so that it cannot read a transponder beyond the middle lance position of that area. o A minimum attenuation distance is 4.5ft. 3 high temperature RFID tags mounted to the top of each oxygen lance. The RFID tag read by both scanners, located in the overlap range, and indicates the active lance. Requires a moderately difficult PLC function to distinguish the oxygen lances locations.

Figure 9 RFID Reader Table 6 Strengths and Weaknesses Concept RFID readers with received signal strength Strengths Requires the fewest number of RFID readers Requires the ultra-high frequency band Weaknesses Succeptable to RFID reader collison RSS is effected by the direct line of sight with the RFID tag
18

Solution to Weakness Requires an anticollision algorithm Requires an RFID tag on every side of each oxygen lance

indication

RSS is a function of the distance between the reader and tag Simple PLC function to convert the RSS into distance into position

RSS is effected by multipath interference Difficult to approximate off site RSS is effected by close proximity between RFID tags

The most cost effective solution The position of the lances are determined by the barcode readers Requires the least amount of complexity No reader collision problems Can be added to any passive RFID system The interrogation zone is adjustable RFID readers with a two element antenna array Operation is not effected by multipath interference RFID reader collision is related to the interrogation zone Requires the ultra-high frequency band Does not require a PLC function to calculate each lance position Requires the fewest number of RFID readers Can be added to any passive RFID system Can be used with physical reflective shielding

Fixed barcode readers have a limited range Operation is effected by magnetic debris

2D Barcode system

Requires additional circuitry increased system complexity Difficult to approximate off site Requires the most number of RFID readers

RFID readers with an antenna multiplexer

Requires complex PLC function to decode the lance positions Limited control over the interrogation zone Requires additional antennas

19

Requires the ultra-high frequency band Immune to RFID reader collision Easily testable off site RFID readers with physical reflecting shielding Can be added to any passive RFID system Does not require a PLC function to calculate each lance position RFID reader collision is related to the interrogation zone

Physical switches are succeptable to environmental damage Difficult to approximate off site Mechanically difficult to adjust Requires the most number of RFID readers Operation is effected by multipath interference

References concerning strengths and weaknesses:


(Nikitin, et al., 2010) (Azzouzi, Cremer, Dettmar, Kronberger, & Knie, 2011) (Bouet & Santos, 2010) (Hansen & Oristaglio, 2000)

20

2.3.5 DOWN SELECTION PROCESS Table 7 Down Selection Process Utility Factors Tracking System Criteria Operating Temperature of reader Operating Temperature of Tag (degree F) Range of the system (ft) Vulnerability to collision (1 = low and 4 = high) Price of system (estimated) Frequency of maintenance (per month) Number of Readers needed (per BOF) Number of Tags needed (per Lance) Weight Data RFID w/ RSSI Utility Weighted Score 0.00 Data Barcode Utility Weighted Score 0.10 RFID Attenuation Data Utility Weighted Score 0.03

0.100

130.00

0.00

145.00

1.00

135.00

0.34

0.150

135.00

0.00

0.00

150.00

1.00

0.15

135.00

0.00

0.00

0.100

8.00

1.00

0.10

1.00

0.00

0.00

4.50

0.50015

0.05

0.100

3.00

0.00

0.00

1.00

1.00

0.10

2.00

0.5

0.05

0.300

3000.00

0.00

0.00

1000.00

1.00

0.30

3000.00

0.00

0.00

0.150

1.00

1.00

0.15

4.00

0.00

0.00

1.00

1.00

0.15

0.075

1.00

1.00

0.08

3.00

0.00

0.00

2.00

0.5

0.04

0.025

3.00

0.00

0.00

1.00

1.00

0.03

3.00

3.00

0.08

0.33

0.68

0.40

(Freedom Technologies Corporation, 2011), (Motorola Solutions, Inc., 2013), (Rockwell Automation, 2013)

21

2.3.6 FINAL DESIGN SELECTION Barcode System . Design Plan and Schedule Ideas will be developed to keep the debris from interfering with the direct line of sight between the tags and the scanners. Ideas will be developed on how to mount the barcode scanners within 1ft. the oxygen lances. A distance measurement will be taken to determine how far down the lance the barcode tags should be placed so that they line up with the stationary barcode scanners. 2.3.7 PRELIMINARY BUDGET Provides the best accuracy and is the most reliable. The system will continuously scan the tags when they are in range, therefore each lance location will be continuously updated. Barcode scanners will transmit the lance ID numbers to the RadioLinx over 802.3 wireless Ethernet. The data is stored in the Controllogix PLC and displayed in Wonderware

In order to determine our preliminary budget we took into account the fact that Arcelor Mittal has all components necessary for the software. This includes the PLC, the card, and the Wonderware system. The purchases that are needed are for the tags and readers only. Since a reader will be needed for each position we will roughly need 15 barcode readers. The barcodes themselves are fairly cheap. We will need some reader samples to test with along with a couple of RFID readers to further set our final design decision in concrete. In the event only one barcode reader is needed for the holding rack the budget would decrease to around $11,000. This estimate includes the potential of all barcode readers, therefore this budget of $20,000 is overestimated

22

allowing fluctuation. (Freedom Technologies Corporation, 2011), (Motorola Solutions, Inc., 2013) Barcode Readers = $1000 * 15 = $15,000 Barcodes = 300 RFID samples = 200 Preliminary budget = $20,000

23

SECTION 3: PROCESS/PROJECT DESIGN STAGE

24

SECTION 4: PROJECT FABRICATION STAGE

25

SECTION 5: PROJECT TESTING AND EVALUATION STAGE

26

SECTION 6: PROJECT MANAGEMENT INCLUDING SCHEDULES


6.1 WORK BREAKDOWN STRUCTURE AND SCHEDULE FOR CONCEPTUAL DESIGN PHASE

27

28

29

30

APPENDICES
TEAM MEETINGS DETAILS

Table 8 Team Meetings Persons Attended Evan Baumis, Taylor Reynolds Evan Baumis, Taylor Reynolds Evan Baumis, Taylor Reynolds Evan Baumis, Dr. Leon-Salas Evan Baumis, Taylor Reynolds Evan Baumis, Taylor Reynolds, Dr. Dunlap Evan Baumis, Taylor Reynolds, Jake Abel, Ken DeGroote Evan Baumis, Taylor Reynolds, Dr. Dunlap Evan Baumis, Taylor Reynolds Evan Baumis, Taylor Reynolds, Dr. Dunlap Evan Baumis, Taylor Reynolds Date 9/5/2013 9/9/2013 9/11/2013 9/17/2013 9/18/2013 9/20/2013 Time 10:00 AM 2:00 PM 6:00 PM 11:00 AM 6:00 PM 1:45 PM Location MGL 1234 KNOY Lobby Hicks Library Leon-Salas Office Hicks Library Dunlap Office Duration 45 min 60 min 75 min 15 min 30 min 45 min

9/24/2013

10:00 AM

Arcelor Mittal, IL

7 hrs

9/25/2013 10/1/2013 10/2/2013 10/3/2013

11:00 AM 10:00 AM 4:30 PM 9:30 AM

Dunlap Office MGL 1234 Dunlap Office MGL 1234

25 min 2 hrs 1 hr 1 hr

31

Evan Baumis, Taylor Reynolds, 10/14/2013 Dr. Dunlap Evan Baumis, Taylor Reynolds, 10/16/2013 Dr. Dunlap Evan Baumis, Taylor Reynolds Evan Baumis, Taylor Reynolds 10/30/2013 11/7/2013

10:30 AM

Dunlap Office (Conf Call w/ Jake Abel) Dunlap Office (Conf Call w/ John Piatek) KNOY Lobby MGL 1234

1 hr

11:15 AM 4:30 PM 1:30 PM

30 min 2 hrs 2 hrs

TRIP REPORTS

ARCELOR MITTAL 9/24/13 Company: Location: Date: Time: Return: Arcelor Mittal Riverdale, IL 09/24/2013 10 A.M. 5:30 P.M.

Total Travel Time: 4 hrs. Total Distance: Contact: 216 mi. Jacob Abel

Attending Persons: Evan Baumis, Taylor Reynolds Description:

32

Upon arriving in Riverdale we met with Jake Abel. Jake is an automation control engineer at Arcelor Mittal. We met him in the visitor center, and from there Jake took us to his office. A brief introduction was conducted and we quickly changed into orange jump suits for our tour through the plant. The facility was a two minute drive from Jakes office. When we arrived at the plant we left to meet with the facility manager, Ken DeGroote. Ken took us into a conference room where we went over the questions we emailed to Jake and Ken a few days before. Things became much clearer for both parties as the questions were answered. Ken drew a picture of the operation of the lances and how they were positioned during the process in the various locations. Ken then gave us the manual to the radiolinx they have there at the facility. Next was to go up to the 6th floor to see the top of the lances. While walking we got a brief tour. It was quickly noticed the amount of dust and dirt throughout the plant. At the top, we were able to observe the water and oxygen connections on the lances which is the area in which the sensor tags will potentially be attached. We were also able to see the various locations and the dimensions of the bay. It was hard to take pictures due to the environment. We then went down to the ground floor to look at the PLC system. It was implied the client wanted to have a wireless system. Upon leaving we were able to take a quick look at the Wonderware operator screen. Ken explained what he preferred to have on the screen as far as information relating to the lances. He then also, explained the screen was easy to adjust to the operators preference. Follow Up Activities: Jake will send us screen shots of Wonderware operator screen Jake will attempt to get a dummy program Jake will send part number of PLC Jake will locate wireless card/information on wireless card We will provide information on potential sensors We will provide information on potential tags We will go over information obtained by visit and forward further questions

33

ARCELOR MITTAL 10/22/13 Company: Location: Date: Time: Return: Arcelor Mittal Riverdale, IL 10/22/2013 7 A.M. 2:30 P.M.

Total Travel Time: 4 hrs. Total Distance: Contact: 216 mi. Jacob Abel

Attending Persons: Evan Baumis, Taylor Reynolds, Dr. Dunlap, Dr. Sanger Description: Upon arriving in Riverdale we met with Jake Abel. Jake is an automation control engineer at Arcelor Mittal. We met him in the visitor center, and from there Jake took us to his office. Jake was open to answer all questions any of us had. We spoke briefly of the history of Arcelor Mittal and the plant at the Riverdale location. Jake then let us know he was able to obtain VPN access for Taylor and me. He created logins for the both of us. He told us he still needed to get our personal computers access. Next we headed to the plant. When we arrived at the plant we left to meet with the facility manager, Ken DeGroote. Ken took us to the BOFs where we spent a good amount of time analyzing the area. We began at the top of the BOF to see where the lances came into contact with the BOF. There Ken and Jake further answered our questions. Things became much clearer for both parties as the questions were answered. It became even more imperative for Taylor and I to obtain a rough outlook of prices of components. Taylor and I presented the idea of barcode scanners. As said before the client prefers RFID however it is ultimately up to us to successfully create a functional system. Next was to go up to the 6th floor to see the top of the lances. Taylor and I began gathering more

34

precise measurements, as our idea is clearer for how the readers work. We set out to measure range between lances and range of each operating area. It was made clear to us that we must think as an operator. We do not want to add any further work for them than already needed. The system needs to be self-operating. Follow Up Activities: Jake will provide full access to Wonderware Jake will be ready to review our concepts Taylor and I will determine concepts Taylor and I will provide itemized list of potential components

35

REFERENCE MATERIAL Azzouzi, S., Cremer, M., Dettmar, U., Kronberger, R., & Knie, T. (2011). New Measurement Results for the Localization of Arrival (AoA) Approach. Germany. Bouet, M., & Santos, A. (2010). RFID Tags: Positioning Principles and Localization. France, Brazil. Finkenzeller, K. (2010). RFID Handbook (3rd Edition ed.). (D. Muller, Trans.) Munich, Germany: John Wiley and Sons, Ltd. Freedom Technologies Corporation. (2011). Hardware Product Line. Retrieved from Freedom Technologies : http://www.freedomcorp.com Hansen, T., & Oristaglio, M. (2000). Method for Controlling the Angular Extent of Interrogation Zones in RFID. Boston, Massachusetts, United States. inLogic. (2013). Passive vs. Active RFID Comparison. Retrieved from http://www.inlogic.com/rfid/passive_vs_active.aspx JPrat. (2009, January). How to Setup EtherNet/IP Messaging with Controllogix. North America: ProSoft Technology. Retrieved September 2013, from Pro-Soft Technology: www.prosoft-technology.com Motorola Solutions, Inc. (2013). Products. Retrieved from Motorola Solutions: http://www.motorolasolutions.com/ Nikitin, P., Martinez, R., Ramamurthy, S., Leland, H., Spiess, G., & Rao, K. (2010). Phase Based Spatial Identification of UHF RFID Tags. Everett, Washington, United States. Rockwell Automation. (2013). Controllogix System.

36

TABLE OF FIGURES Table 1 Requirements................................................................................................................... 10 Table 2 Various aspects of systems and options .......................................................................... 12 Table 3 Concept Selection............................................................................................................ 13 Table 4 Preliminary Strengths and Weaknesses .......................................................................... 13 Table 5 Specifications of various components ............................................................................. 14 Table 6 Strengths and Weaknesses .............................................................................................. 18 Table 7 Down Selection Process Utility Factors .......................................................................... 21 Table 8 Team Meetings ................................................................................................................ 31

Figure 1 Positions above BOF (North, active, South respectively) ............................................... 6 Figure 2 Holding rack in bay with multiple oxygen lances ........................................................... 6 Figure 3 Area of Operation ............................................................................................................ 7 Figure 4 Concepts and Respective Solutions ............................................................................... 15 Figure 5 Three Conceptual Designs Diagram .............................................................................. 16 Figure 6 RFID Tag ....................................................................................................................... 17 Figure 7 Simple Mountable Barcode Scanner ............................................................................. 17 Figure 8 2D Barcode .................................................................................................................... 17 Figure 9 RFID Reader .................................................................................................................. 18

37

You might also like