Originally built and commissioned by SMS group, the facility produces high-quality flat carbon steel products across a wide range of grades and dimensions and occupies a key position in thyssenkrupp Steel Europe’s production portfolio.
As part of a project aimed at improving efficiency, reliability, and digital readiness, Level 1 automation and human–machine interface (HMI) systems were upgraded for the three downcoilers at the hot strip mill. The modernization was designed to eliminate operational challenges caused by obsolete spare parts and outdated operating systems. The project was successfully completed with the implementation of an upgraded technological control system (TCS) and enhanced HMI solutions, significantly optimizing downcoiler operations.
At the core of the modernization was the integration of SMS group’s proven X-Pact® ProBAS software platform with X-Pact® Embedded control units. This setup ensures seamless, high-speed control performance, while the EtherCAT real-time Ethernet network enables reliable communication with high-speed sensors. Standard sensors are supported via the PROFIBUS remote I/O system. In addition, HMI upgrades introduced ergonomic operator panels and modern visualization tools, improving user interaction and fault diagnostics. Together, these measures ensure high system availability and establish a solid foundation for future digitalization initiatives.
The project forms part of the long-standing partnership between thyssenkrupp Steel Europe and SMS group. Within the framework of this continuous modernization program tailored to the Duisburg plant, several major upgrades have been implemented over the years. In 2024, Level 2 process automation was adapted to enable a wider range of setup options. In 2019, rotary table systems incorporating 90 drives were integrated into SMS group’s automation system. Earlier milestones include comprehensive improvements to the side guide control system in 2017, and the conversion of coil transport and tracking systems for a new lifting table in 2013.
Commenting on the project, Michael Wirtz, Service Manager Flat Products Solutions at SMS group, said:
“Our lifecycle service approach ensures that automation systems remain reliable and up to date. With this latest upgrade, we have implemented high-speed control and modern communication technologies to support efficient and stable operations at the hot strip mill.”
Wirtz also emphasized that the X-Pact® Service agreement in place since 2009 has strengthened the long-term partnership with thyssenkrupp Steel Europe, enabling the plant to be optimized sustainably and reliably.
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