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Corematic Engineering Smelting
Safe Hot Metal Bridle Lifting
Proximity Warning System for Overhead Crane in Potline
Pot Hood Removal Robot for Potline Crane
Automatic Anode Gauging
Rod Assembly Cracking Detection
3D Scanning Defect Detection Rod Assembly
Safe Hot Metal Bridle Lifting
Safe Hot Metal Bridle Lifting - Case Study corematic_engineering_industry40

RIO TINTO

Service
Consulting, Designing & Commissioning

Product
Infrared 3D Camera

Overview

Corematic engineering has been engaged to provide a solution to an aluminium smelter in order to reduce the risk of lifting hot metal. When engaging the bridle with the ladle, the non-invasive system designed to provide a constant and reliable indication that the ladle is fully engaged prior to lifting.

 

Outcome

  • Non-invasive solution
  • Designed for pot line crane or cast house crane
  • Off the shelf parts
  • Plug and play

 

Benefit

  • Considerably reduce the risk of dropping the ladle
  • Provide trust signal to the operator
  • Low cost
Proximity Warning System for Overhead Crane in Potline
corematic_engineering_industry40_potline_case_study_overhead_proximity_warning_system

RIO TINTO

Service
Consulting, Designing & Commissioning

Product
Smart Alert

Overview

Corematic Engineering has been engaged to review an existing proximity warning system designed by the customers. During the design review, the team has suggested an alternative technology that will divide the planned CAPEX by four. The system uses fewer components and a more affordable technology without compromising with the original requirements. In fact, the solution exceeds the client specification. Our system has been designed for the harsh pot line environment and is integrated into the crane HMI.

 

Outcome

  • 40m detection range
  • Customisable detections zone
  • 2-way detection
  • Lighting, dust, fume independent
  • Compact

 

Benefit

  • CAPEX considerably reduced thanks to the consulting phase
  • Scalable solution
  • Off the shelves parts and components
  • Risk of collision reduce for a safer workplace
Pot Hood Removal Robot for Potline Crane
corematic_engineering_industry40_automation_scott_hansen_rio_tinto_potline_lidar_3d_scanning_case_study_infrared

RIO TINTO

Service
Consulting, Designing & Commissioning

Product
Infrared 3D Camera & LiDAR

Overview

Confidential

 

Outcome

  • Confidential

 

Benefit

  • Confidential
Automatic Anode Gauging
corematic_engineering_industry40_services_installation_Rio-Tinto-Anode-Gauging-Potline

RIO TINTO

Service
Consulting, Designing & Commissioning

Product
Solid State LiDAR

Overview

Confidential

 

Outcome

  • Confidential

 

Benefit

  • Confidential
Rod Assembly Cracking Detection
corematic_engineering_industry40_smelter_pot_lines_scanning
corematic_engineering_industry40_smelter_pot_lines_scanning_rod
corematic_engineering_industry40_smelter_pot_lines_scanning_laser

RIO TINTO

Service
Consulting

Product
LiDAR

Overview

Corematic was approached by an aluminium smelter to come up with a solution to reduce the risk of production issues and safety concerns by designing a system that’s able to scan and review the production system and check for weld crack failures. Weld cracks become an issue when product travelling down system lines accumulate in these small fractures.

The specifications given for the scanner was to be able to detect crack failure wider than 2mm and deeper than 10mm. This 2 day event was a feasibility trip to test and verify our hardware for scanning and mapping in the field. We were able to verify that the scanner works, beating expectations and producing full 3d reconstructed mapping of weld cracks no less than 1mm wide and scan the lines for transfer deposits that could cause blockages.

Our non-invasive camera techniques meant production could continue with minimal impact. Following on from this trip we’re able to provide the client with a report and our recommendations for a full monitoring system based on our live field environment testing.

 

Outcome

  • 1mm wide & 10mm deep weld crack detection
  • Full 3d reconstruction mapping of lines for deposits & cracks
  • Futuristic technology created for smelter specific equipment
  • Non-invasive scanning techniques

Benefit

  • Concept creation within a week
  • Feasibility study and implementation in 2 days
  • Preventative and predictive measures 
  • Exceeded specifications of measurements in scanning
3D Scanning Defect Detection Rod Assembly
corematic_engineering_industry40_rod_assembly_detection_3d_scanning
corematic_engineering_industry40_rod_assembly_detection_3d_scanning_map

BELL BAY

Service
Consulting

Product
Pre-feasibility Study Report

Overview

Bell Bay Aluminium engaged Corematic to conduct a feasibility study on 3D scanning technology to identify defects in their stub and rod assemblies. The technology had to meet specific requirements in its measurements. The equipment in these fleets require regular maintenance in order to remain efficient and safe in operations. 2D technology had been previously tested but with limited information received by the client, 3D technology was the next option to try.
Corematic were commissioned to conduct a study on 3D scanning technology for these assembly lines, and provide a comparative report on the findings. Two different scanning equipment setups were taken onsite for testing. A report was produced for the client with thorough findings regarding functional capabilities and limitations, cost, and integration options. A comparison list between the technology was provided along with recommendations from the engineers based on findings and clients specifications
Outcome:
  1. Onsite testing - relevant to client
  2. Unbiased technology options suggested
  3. Options presented with specifications met
  4. Feasibility report on technology
  5. Recommendations provided
Benefits:
  1. Direct collaboration with client for specifications
  2. Feasibility study in 2 days
  3. Unbiased options provided
  4. Reality of environment tested
  5. In depth knowledge provided on equipment