Primetals Technologies Completes World’s First Robotic Coil Trimming System Installation at Hyundai Steel!

Primetals Technologies has successfully completed the installation and commissioning of TrimRob, the world’s first foundry-rated robotic coil trimming and sampling system, at Hyundai Steel’s wire rod mill in Dangjin, South Korea. Following successful commissioning, the company has received the Final Acceptance Certificate (FAC), confirming that the system has met all contractual performance and operational requirements. The project was delivered in collaboration with Polytec, a global specialist in robotic automation solutions.

The successful deployment marks a significant milestone in the automation of steel manufacturing processes, introducing a fully autonomous solution for trimming and sampling hot wire rod coils. By replacing labour-intensive manual operations with intelligent robotic technology, the new system is expected to significantly improve workplace safety, enhance operational efficiency, and deliver greater consistency in product quality while supporting Hyundai Steel’s smart manufacturing initiatives.

Wire rod production is one of the most demanding processes in steel manufacturing, with coils being produced approximately every minute at temperatures exceeding 1,000°C. Traditionally, trimming the head and tail of each coil and collecting quality samples requires two to four operators per shift, who manually perform the task using handheld cutting tools. The process exposes workers to extreme heat, repetitive physical movements, and potentially hazardous operating conditions while maintaining stringent production quality standards.

TrimRob has been specifically developed to eliminate these operational challenges by automating the complete trimming and sampling process. The system integrates advanced robotics, intelligent machine vision, and specialised cutting technology to perform the entire operation without direct operator intervention. This not only removes personnel from hazardous work environments but also delivers greater precision and repeatability throughout the production process.

At the heart of the solution is an advanced machine vision system capable of analysing each wire rod coil in real time. Using sophisticated image-processing algorithms, the system identifies individual wire rings, detects tangles, overlapping sections, and irregular coil formations before automatically determining the optimal cutting location. This intelligent processing enables highly accurate trimming regardless of variations in wire diameter, coil geometry, or steel grade, ensuring consistent sample preparation and improved production efficiency.

The robotic trimming unit is equipped with a specially engineered cutting tool designed to withstand the harsh conditions found in hot rolling environments. Built to operate reliably under extreme temperatures and demanding industrial conditions, the system delivers precise cuts while maintaining high production throughput and reducing process variability.

According to Ravindra Goyal, Head of Process at Primetals Technologies USA, automation is playing an increasingly important role in the global steel industry as manufacturers seek to improve productivity while creating safer working environments. He explained that TrimRob significantly reduces the risk of repetitive strain injuries and workplace accidents by removing operators from dangerous production areas, allowing employees to focus on higher-value operational and supervisory responsibilities within the manufacturing process.

Extensive factory acceptance testing conducted at Hyundai Steel’s Dangjin facility confirmed that the robotic system successfully achieved all agreed operational and performance targets. During testing, TrimRob consistently maintained the required production cycle times while processing wire rods ranging from 5.5 mm to 20 mm in diameter across multiple steel grades and varying material strengths. The successful validation demonstrated the system’s ability to operate reliably under a wide range of production conditions.

The automated solution has also been engineered to improve quality assurance within the wire rod manufacturing process. TrimRob accurately cuts the precise sample length required for laboratory inspection or, when metallurgical testing requires, one additional wire ring. By consistently producing samples that meet specification without cutting below the required length, the system enhances quality control, reduces material waste, and improves process reliability throughout production.

The successful implementation at Hyundai Steel demonstrates the growing adoption of robotics, artificial intelligence, and machine vision technologies across the global metals industry. As steel manufacturers increasingly pursue Industry 4.0 strategies, intelligent automation solutions such as TrimRob are helping improve manufacturing efficiency, product consistency, workplace safety, and overall plant productivity while addressing ongoing labour shortages and rising operational demands.

With the successful completion of the world’s first industrial deployment of TrimRob, Primetals Technologies has established a new benchmark in steel manufacturing automation. The project highlights how advanced robotics can transform traditional hot rolling operations by delivering safer, smarter, and more efficient production processes, supporting the steel industry’s continued transition towards highly automated and digitally connected manufacturing facilities.