Category: Automation Solutions

Date: 2022-2024

Kayalar Copper Alloys Inc., established in 1958, has become one of the leading companies in Turkey in the production of sheets, strips, coins, and token blanks made from copper and copper alloys, with a commitment to technological advancement and quality understanding.

At Kayalar Copper, significant upgrades have been successfully completed as part of the Cold Rolling ABB 800xA Automation System revisions, including HMI upgrades, integration of the ABB thickness measurement system with the AGC (Automatic Gauge Control) system, and projects for data collection from production lines.

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Project Scope and Completed Projects

ABB 800xA HMI Revisions: The HMI system has been updated to provide a more intuitive and user-friendly interface for operators to monitor and control production processes. The new interface enhances operational visibility, allowing operators to respond more quickly to issues.

Integration of ABB Thickness Measurement System and AGC (Automatic Gauge Control): The ABB thickness measurement system has been integrated with the AGC system to ensure consistent thickness across all production lines. This integration allows for real-time monitoring and automatic adjustments during the rolling process, thereby improving product quality and minimizing material waste.

Production Data Collection Projects: Data collection systems have been implemented to gather real-time production data from various lines. These systems facilitate seamless communication with the automation infrastructure and provide valuable insights for process optimization, enabling better decision-making and proactive maintenance.

Category: AUTOMATION SOLUTIONS

Date: 2019-Still Ongoing.

At VIG Metal, one of Turkey’s leading flat aluminum manufacturers, we successfully completed several automation projects within the scope of the Cold Rolling ABB 800xA Automation System. These projects focused on improving precision in production processes, increasing efficiency, and advancing digitalization across operations.

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Completed Projects

• Gear Shift Automation:
  Automatic gear ratio adjustments were implemented based on production speed and material structure, enabling more flexible operations and reducing downtime.
• Pass-Line Adjustment:
  The automatic height adjustment of the production line was optimized to ensure the proper flow and positioning of materials. This improvement helped prevent material deviations and errors.
• Roll Transfer Car Automation:
  The roll transfer car automation was designed to enable the quick and safe replacement of rolls, minimizing downtime and increasing overall line efficiency.
• Thickness Measurement System Integration:
  The ABB Thickness Measurement System was integrated with the automation infrastructure to enable real-time monitoring of material thickness at every stage of production. This system provides operators with the ability to intervene instantly, ensuring superior product quality.
• Centering Measurement System Communication:
  The communication between thickness and centering measurement devices and the automation system enhanced precision and raised quality standards across the production line.
• Coil Barcode System Installation:
  A barcode system was installed to track each coil throughout the production and shipping processes. This system streamlined traceability, accelerated stock management processes, and enabled quick responses to production errors through digital monitoring.

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These comprehensive automation initiatives have made VIG Metal’s production line more flexible, energy-efficient, and labor-efficient while significantly improving quality control processes. We are proud to contribute to the digital transformation of VIG Metal and enhance their operational performance.