SMS group has modernized the automation systems of the downcoilers in hot strip mill No. 1 at thyssenkrupp Steel Europe

• Modernization of level 1 automation and HMI has resolved issues caused by outdated spare parts and legacy operating systems
• The upgrade introduces high-speed control and robust communication networks, enhancing overall operational efficiency
• A lifecycle service approach ensures continuous plant operations and availability 

SMS group has successfully completed the modernization of the automation systems in the coiler area of hot strip mill No. 1 at thyssenkrupp Steel Europe in Duisburg. Originally built and put into service by SMS, the mill produces high-quality carbon steel flat products in a wide range of grades and dimensions. As a core element of thyssenkrupp Steel Europe’s production portfolio, the facility has been systematically upgraded to ensure efficiency, reliability and digital readiness.

The project focused on updating the level 1 automation and human machine interface (HMI) systems for the mill’s three downcoilers, addressing challenges posed by outdated spare parts and legacy operating systems. It concluded with the successful implementation of the technological control system (TCS) and HMI enhancements, significantly optimizing downcoiler operations.

Central to this modernization was the integration of SMS group’s proven X-Pact^® ProBAS software platform combined with X-Pact^® Embedded controllers. This setup provides the high-speed control performance essential for seamless operation. An EtherCAT real-time Ethernet network now enables robust communication between high-speed sensors, while a PROFIBUS remote I/O system supports standard sensors. Furthermore, the HMI upgrade introduced modern visualization with ergonomic faceplates, improving user interaction and diagnostic capabilities. These measures ensure continuous plant availability and create a strong foundation for future digitalization initiatives.

The project builds on a longstanding partnership between thyssenkrupp Steel Europe and SMS group, defined by continuous modernization steps tailored to the Duisburg facility. Previous upgrades include:

• 2024: Level 2 process automation adaptations for more varied setting values
• 2019: Integration of run-out roller tables (involving 90 drives) into SMS group’s automation system
• 2017: Extensive enhancements to the side guide control system
• 2013: Conversion of coil transport and tracking systems for the new lifting table

“Our lifecycle service approach ensures that automation systems remain reliable and up to date. With this recent upgrade, we have implemented high-speed control and modern communication technologies to support efficient and stable operations at the hot strip mill,” said Michael Wirtz, Service Manager for Solutions Flat Products at SMS group. “Our X-Pact^® Service contract, in place since 2009, underscores our partnership with thyssenkrupp Steel Europe and enables us to sustainably and reliably optimize the plant.”