The "Automated Coating Control Using Regression Approach Towards Enterprise 5.0 (ACCURATE 5.0)" project is an innovative system designed to predict, monitor, and control zinc coating weight in continuous galvanizing lines using Machine Learning, IoT, and Cloud Computing technologies. It was developed by a Team of Two Young Managers from CRM-III department, Prashant Kumar Singh (Sr. Mgr/CRM-III) and Parichay Bhattacharjee (Manager, CRM-III). The system uses a dataset of 30,000+ tuples to perform Multivariate Polynomial Regression Analysis and dynamically arrive at an equation for predicted coating weight.
The equation is then displayed in the SCADA for the operator to modify values with real-time feedback of line speed, air pressure, horizontal position, and lip gap from the field if required. The regression coefficients are tuned every month and is presently operating at an accuracy of (+1 GSM) (more than 99% accuracy). The project was developed from scratch and required no special hardware, making it a zero-cost project. Notably, the system was integrated with existing automation systems and provides benefits such as reduced zinc consumption and improved product quality.
The challenges faced during the project were difficulty in data collection for decision-making, which was overcome by developing novel ACCURATE 5.0 data acquisition module, and difficulty in achieving sufficient accuracy, which was overcome by tuning the regression coefficients using artificial intelligence. Overall, the ACCURATE 5.0 system is a cost-effective and efficient solution for predicting, monitoring, and controlling zinc coating weight in galvanized products. The project has brought about annual recurring cost savings of INR 17.83 Crores. The team developing and implementing the project, Prashant Kumar Singh and ParichayBhattacharjee recently showcased their solution in the CII ER Productivity awards and Won the First Prize for SAIL, Bokaro Steel Plant.
The team has also successfully filed an Indian patent on behalf of SAIL to secure the technology and design of their invention.
