Predictive Maintenance in Continuous Casting and Rolling (CCR) Plants
The metallurgical sector is increasingly adopting predictive maintenance systems to enhance the availability, reliability and lifespan of production assets. Continuous Properzi is carrying forward the development of a preventive and predictive maintenance program for the Continuous Casting and Rolling (CCR) lines producing copper and aluminum rod. The approach combines real-time sensor-based monitoring of temperatures, vibrations and radial/axial displacements with Industry 4.0 technologies such as big data analytics and cloud-based processing to anticipate possible failures and optimize maintenance planning. Case studies on rolling mill gear transmissions and coiler gearboxes demonstrate how early detection of mechanical anomalies reduces unplanned downtime, extends equipment lifetime, and decreases operational costs. Experimental validation on a MicroMill line confirmed the capability of early fault detection, enabling scheduled shutdowns, reducing spare parts consumption and improving operational safety.