• Corrosion Science and Technology
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• v.10 no.1
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• pp.30-36
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• 2011

The effect of dynamic flow or forced convection were investigated and compared on the formation of inhibition layer, galvanizing and galvannealing reactions through the hot-dip galvanizing simulator with the oscillation of specimen in zinc bath, continuous galvanizing pilot plant with zinc pumping system through the snout and continuous galvanizing operation with Dynamic $Galvanizing^{TR}$ system. The interfacial Al pick-up was not consistent between the results of simulator, pilot plant and line operation, but the morphology of inhibition layer became compact and refined by the forced convection. The growth of Fe-Zn intermetallics at the interface was inhibited by the forced convection, whereas the galvannealing rate would be a little promoted.

• International Journal of Control, Automation, and Systems
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• v.2 no.1
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• pp.55-67
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• 2004

In this paper, an active vibration control of a translating steel strip in a zinc galvanizing line is investigated. The control objectives in the galvanizing line are to improve the uniformity of the zinc deposit on the strip surfaces and to reduce the zinc consumption. The translating steel strip is modeled as a moving belt equation by using Hamilton’s principle for systems with moving mass. The total mechanical energy of the strip is considered to be a Lyapunov function candidate. A nonlinear boundary control law that assures the exponential stability of the closed loop system is derived. The existence of a closed-loop solution is shown by proving that the closed-loop dynamics is dissipative. Simulation results are provided.

• Journal of Advanced Marine Engineering and Technology
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• v.26 no.2
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• pp.192-199
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• 2002

In continuous galvanizing process, the mass of zinc deposited and its distribution are controlled by the air pressure, effective distance from the air knife nozzle to the steel strip surface and line speed. Coating defects are resulted from the unbalance of these control factors and the inaccuracy of coating equipments. This paper investigates the main cause of coating deviation and a new air knife system for control of coating thickness was developed. We investigate dynamic pressure variation by air knife types. It is found that the coating deviation is caused by the unbalance of dynamic pressure, the irregularity of strip position, and the strip vibration. Formulating a useful coating model by using present working condition, an optimal working condition is suggested. The productivity and coating quality are improved by applying the result of this research at the shop floor.

• Journal of Institute of Control, Robotics and Systems
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• v.21 no.8
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• pp.718-722
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• 2015

This paper proposes a fractional-order PID (Proportional-Integral-Derivative) control used electromagnetic strip stabilization controller in a continuous galvanizing line. Compared to a conventional PID controller, a fractional-order PID controller has integration-fractional-order and derivation-fractional-order as additional control parameters. Thanks to increased control parameters, more precise controller adjustment is available. In addition, accurate transfer function of a real system generally has a fractional-order form. Therefore, it is more adequate to use a fractional-order PID controller than a conventional PID controller for a real world system. Finite element models of a $1200{\times}2000{\times}0.8mm$ strip, which were extracted using a commercial software ANSYS were used as simulation plants, and Gaussian mixture models were used to find optimized control parameters that can reduce the strip vibrations to the lowest amplitude. Simulation results show that a fractional-order PID controller significantly reduces strip vibration and transient response time than a conventional PID controller.

• Corrosion Science and Technology
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• v.10 no.2
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• pp.43-46
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• 2011

Zinc consumption in a continuous galvanizing line is one of the highest operating cost items in the facility and minimizing zinc waste is a key economic objective for any operation. One of the primary sources of excessive loss of zinc is through the formation of top dross and skimmings in the coating pot. It has been reported that the top skimmings, manually removed from the bath, typically consist of more than 80% metallic zinc with the remainder being entrained dross particles ($Fe_2Al_5$) along with some oxides. Depending on the drossing practices and bath management, the composition of the removed top skimmings may contain up to 2 wt% aluminum and 1 wt% iron. On-going research efforts have been aimed at in-house recovery of the metallic zinc from the discarded top skimmings prior to selling to zinc recycling brokers. However, attempting to recover the zinc entrapped in the skimmings is difficult due to the complex nature of the intermetallic dross particles and the quality and volume of the recycled zinc is highly susceptible to fluctuations in processing parameters. As such, an efficient method to extract metallic zinc from top skimmings has been optimized through the use of a specialized thermo-mechanical process enabling a continuous galvanizing facility to conserve zinc usage on-site. Also, through this work, it has been identified that filtration of discrete dross particles has been proven effective at maintaining the cleanliness of the zinc. Future efforts may progress towards expanded utilization of filters in continuous galvanizing.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.08a
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• pp.111-118
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• 1999

This article describes the basic engineering concepts to be considered in the application of an induction heating furnace in the hot-dip galvanizing line. Experience in the Dongkuk project in Pohang, has shown that this arrangement has many advantages over the conventional method of using a combustion-gas heated furnace. Investment and operating costs are lower, the line length is much shorter, line operation is more convenient, air pollution is reduced, and the coated strip at of top-quality. As these benefits become well known, it is anticipated that the concept of induction heating will be more widely used in both new and revamped process lines. Induction heating is suitable for the production of Commercial Quality hot galvanized coils. More research is required to extend the present concept to the production of higher forming grades such as Drawing, Deep Drawing and Extra Deep Drawing Quality steels. A combination of induction heating and combustion-gas heating may lead to the way to the processing of these qualities of strip.

• Proceedings of the Korean Institute of Surface Engineering Conference
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• 2001.11a
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• pp.14-14
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• 2001

• Journal of Mechanical Science and Technology
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• v.18 no.7
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• pp.1074-1085
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• 2004

There are many intermediate web guides in cold rolling mills process such as CRM (cold rolling mill), CGL (continuous galvanizing line), EGL (electrical galvanizing line) and so on. The main functions of the web guides are to adjust the center line of the web (strip) to the center line of the steel process. So they are called CPC (center position control). Rapid process speed cause large deviation between the center position of the strip and the process line. Too much deviation is not desirable. So the difference between the center position of the strip and the process line should be compensated. In general, the center position control of the web is obtained by the hydraulic driver and electrical controller. In this paper, we propose modelling and several controller designs for web-guide systems. We model the web and guide by using geometrical relations of the guide ignored the mass and stiffness of the web. To control the systems, we propose PID controllers with their gains tuned by the Ziegler-Nichols method, the H$\_$$\infty$/ controller model-matching method, and the coefficient diagram method (CDM). CDM is modified for high order systems. The results are verified by computer simulations.

• 제어로봇시스템학회:학술대회논문집
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• 1995.10a
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• pp.323-327
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• 1995

A new air knife system for coating thickness control in hot dip galvanizing process had been developed and installed on the CGL in Pohang Steel Works, POSCO. This new system consists of air knives with remotely adjustable nozzle slot and an automatic control system which can control both longitudinal and traverse coating deviations. Based on the optimal control algorithm, a traverse coating deviation control was designed. The controller controls the lip profile of the air knives with flexible structure according to the deviation of coating weight. From the measured values which are dependent on the strip width, the lip gaps are calculated with optimal algorithm and the model of the coating deviation. Time delay between knives and a coating thickness gauge is solved by the Smith Predictor.

• Journal of the Korean institute of surface engineering
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• v.29 no.2
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• pp.132-139
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• 1996

Experiments on the automatic control of NaOH concentration and on the spraying condition of NaOH solution in the alkaline degreasing process of a continuous hot-dip galvanizing line have been carried out in order to improve degreasing performance of a galvanizing sheet steel using laboratory degreasing and galvanizing simulators. The concentration of NaOH for the good degreasing has been determined to be 6.0% and more and this concentration has been able to be automatically well controlled within $\pm$0.1% by employing a solution electrical conductivity meter under a flow injection analysis condition rather than by employing a sodium ion selective electrode in the degreasing simulator. Frequent blocking of the spraying nozzles of the solution has been reduced considerably by the set-up and periodical operation of an automatic valve system in the nozzle system. By applying this automatic valve system and by automatic controlling the NaOH concentration and other ordinary variables in the degreasing process, the degreasing performance has been increased from the conventional 76% to the new 85%.