POSCO Group does its best to develop technologies that contribute to safety and carbon neutrality. We introduce POSCO Group’s excellent new technologies to create a better world! In this edition, we spotlight POSCO’s revolutionary One-Touch Converter Operation Automation Technology. With a single press of a button, this cutting-edge innovation fully automates converter operations to ensure operator safety while maintaining consistently superior operating quality.

▲ After successfully completing one-touch operation of the No. 2 steelmaking furnace at Gwangyang works on October 24, Head, Gwangyang Works Dong-ryeol Lee and employees are taking a commemorative photo.

Have you heard of the term Intelligent Factory? An Intelligent Factory actively introduces core technologies of the Fourth Industrial Revolution, such as IoT, AI, and big data, to redefine efficiency and innovation. Unlike traditional “lighthouse factories,” Intelligent Factories take things further by autonomously collecting, integrating, and analyzing data in all processes for smart, data-driven decision making. In October, POSCO made a significant stride toward realizing the Intelligent Factory vision by developing One-Touch Converter Operation Automation Technology. This innovation automates the entire steelmaking process, removing impurities from molten iron from the blast furnace to produce clean steel with just a single press of a button.

POSCO’s one-touch technology applies AI to complete all converter operations without human intervention. The system also automates post-conversion processes such as tapping, slag separation, and coating, by integrating IoT-enabled vision measurement systems that collect and analyze visual data, which is then processed through AI. With this technology development, operators can monitor and manage operations remotely anytime, anywhere without manual control for safety, efficiency, and convenience.

The Need for Digital Transformation in Operating Environments

At Gwangyang works, which produces 22 million tons of crude steel annually, the converter operations in the steelmaking plant demand meticulous control by skilled operators. Each set of three converters required the involvement of 11 operators to manage the processes effectively. Molten steel reaches temperatures exceeding 1600°C and weighs up to 300 tons, which puts immense pressure on operators who must perform their tasks with the utmost care in very demanding conditions. This raised concerns about workplace safety and the need for automation technologies to ensure worker safety. Moreover, digital transformation of traditional operating methods was needed to adapt to the evolving steel industry paradigm. In 2018, POSCO’s Gwangyang works Steelmaking Division teamed up with POSCO’s Research Institute of Technology to develop intelligent, autonomous manufacturing processes that prioritize cost efficiency, quality, and safety.

Gwangyang works’ steelmaking plant had confidence in its ability to develop automation technologies due to the large number of experienced operators and vast operational data accumulated over years of production. After seven years of relentless effort, the team achieved the remarkable milestone of automating the process and reducing the 25 existing manual operations to just a single touch of a button. Let’s take a look at the three key pillars of One-Touch Converter Operation Automation Technology.

IoT-Powered Vision Measurement and Control System Automates Tapping Operations

In converter operations, where 1.5 tons of molten steel are tapped every second, the extreme heat and weight required operators to visually monitor and manually control equipment. To solve this problem, POSCO focused on automating the tapping process, one of the most complex stages in converter operations. IoT-based cameras and vision measurement devices were installed around the converter to collect years of data. This data was processed using computer vision technology, and control logic incorporated the extensive expertise of experienced operators. As a result, POSCO achieved full automation of tapping operations. Additionally, a system was established to monitor blind spots and high-risk areas to replace manual observation and prevent hazardous situations.

POSCO’s Signature AI Converter Model Hits 97% Accuracy in Temperature and Composition

Converter heat matching involves calculating the total thermal energy of molten iron, scrap, and auxiliary materials introduced into the converter. POSCO has improved this critical task by harnessing three years of accumulated operational big data and seamlessly integrating it with AI to develop a sophisticated algorithm. This innovation made it possible to produce consistent, high-quality steel, even in dynamic and variable operating environments. The developed model achieved a remarkable 97% accuracy in temperature and composition prediction, a level comparable to the expertise of top-grade operators.

Digital Twin-Enabled One-Touch Automation Integrates and Remotely Controls Processes

The digital twin system digitally replicates physical objects for real-time synchronization and interaction between virtual and physical environments. By implementing a virtual converter synchronized with real-time operations, POSCO achieved integrated management and monitoring capabilities. This advancement also enabled the creation of a system where operators can remotely control the converter process with a single touch anytime, anywhere.

▲A demonstration of the one-touch automation system held at the POSCO Center in Seoul on October 24.

▲(left) After the system demonstration, POSCO President Si-woo Lee is taking a photo with Gwangyang works Steel Department General Technical Manager Deung-mo Choi. (right) galvanized steel sheet (EG 1500Mart steel) produced through remote Converter one-touch operation.

On October 24, a demonstration of the One-Touch Automation System was held at POSCO Center in Seoul. POSCO President Si-woo Lee successfully initiated the remote operation of Gwangyang works’ No. 2 converter to produce top-grade automotive steel.

▲ The Gwangyang works Steelmaking Department team won the grand prize, the ‘Innovation Award’, at the ‘2024 POSCO Technology Awards’ (Fifth from the left, In-hwa Chang, Chairman of POSCO Group)

One-Touch Converter Operation Automation Technology is a cornerstone of POSCO’s transformation into an Intelligent Factory. It was recognized for its innovative capabilities by winning the Innovation Award at the ‘2024 POSCO Group Tech Forum’ held in POSTECH’s main auditorium on November 6.

The introduction of this technology has transformed the work environment for operators by alleviating their workload and reducing concerns about safety risks. Beyond these benefits, the accuracy of the temperature and composition of molten steel was improved from 94% to 97%, while the error rate in steelmaking decreased to maintain consistent product quality. These advancements are projected to yield annual economic benefits of approximately KRW 33.8 billion.

POSCO has also unveiled a roadmap to expand the use of One-Touch Converter Operation Automation Technology from Gwangyang works to Pohang works and its Indonesian works in the near future. Get ready to witness POSCO redefine the future by spearheading groundbreaking innovation and making a bold leap into the era of Intelligent Factories!

POSCO Group does its best to develop technologies that contribute to safety and carbon Reduction. We introduce POSCO Group’s excellent new technologies to create a better world! In this episode, we explore POS-VISION, a solution from POSCO E&C that utilizes drones equipped with high-definition imaging equipment to manage the concrete exterior walls of apartments.

Developed by POSCO E&C in January 2024, POS-VISION utilizes drones equipped with high-definition imaging equipment to precisely identify and manage the width, length, and location of cracks in the concrete exterior walls of structures such as apartments and bridges.

POS-VISION combines drone operation technology with artificial intelligence to enable crack recognition, high-definition image processing, and the elimination of false detection elements. This integration allows construction managers to access detailed information about the exterior walls of buildings, facilitating seamless quality management.

In January 2022, an incident involving the collapse of an apartment by Company H highlighted the crucial need for enhanced quality management of large concrete structures at POSCO E&C’s New Growth Future Technology Research Institute, Construction Automation Section.

Quality checks were thorough in indoor areas such as underground parking lots and individual units where cracks were visible, but the exterior walls presented challenges due to less visible cracks. These exterior wall cracks are significant not only for structural stability but also for their potential to cause leaks and corrosion. Unaddressed, they could lead to concrete deterioration and exposed rebar, jeopardizing the brand’s reputation. Prompted by these risks, the team embarked on an in-depth investigation of these quality management challenges, developed the concept of POS-VISION, and initiated full-scale technical development.

Initially, the team conducted thorough research on the condition and management of cracks in large concrete structures, such as apartment buildings. According to standards for assessing defects in residential housing, cracks measuring 0.3 mm or wider are classified as defects. Moreover, any penetrating cracks,* even those under 0.3 mm wide, also qualify as construction defects. This highlights the need for precise crack measurement technology, as different widths of cracks require different repair methods.

*Penetrating Cracks: These are cracks that run from an exterior to an interior surface within the same section and are often seen as temperature-related in thick walls or as shrinkage cracks in slabs.

In response, the team developed a sophisticated AI-driven image analysis technology. They refined POS-VISION’s accuracy through tests with real-world field data. For estimating the dimensions of cracks in images taken by drones, they applied geometric principles inherent to the camera’s functioning, enabling precise measurements of the distance between pixels.

▲Conceptual diagram (left) and GSD calculation formula that formed the basis for the development of POS-VISION technology.

To measure the actual distance between pixels, the ground sample distance (GSD) concept was utilized. This term describes the distance between the centers of two adjacent pixels A smaller GSD indicates higher precision and accuracy of the data. Nonetheless, there were challenges due to the physical constraints encountered when drones flew close to buildings for detailed shots. To address these issues, the team implemented a super-resolution algorithm that upgraded the images to a resolution superior to their original quality. They used the outcomes from field trials as a foundation for further validation and enhancement, thus improving the system’s reliability. Through multiple tests, it was established that the best distance for the drone from the building should be 4 meters. This distance allowed for accurately distinguishing between cracks measuring 0.3 mm and 0.5 mm, which is vital for selecting the correct concrete repair and reinforcement techniques.

*Ground Sample Distance (GSD): Measures the distance between the centers of two consecutive pixels.

Besides considering the shooting distance, several other factors were important. Drones, which rely on satellite signals to navigate and determine their positions, face challenges within high-rise apartment complexes where these signals are often weak. This increases the potential for drones to collide with buildings. Therefore, the expertise and proficiency of the drone operators play a vital role in achieving safe and precise measurements.

▲Inspecting cracks while maneuvering the drone.

Given that the operations take place outdoors, weather significantly influences the process. Windy conditions heighten the risk of drone collisions, while cloudy, rainy, or snowy weather complicates visibility. Additionally, operating drones for extended periods in extremely hot or cold temperatures is challenging. In response, POSCO E&C is considering the development of autonomous drones designed to handle these challenges and environmental factors effectively.

To help users swiftly pinpoint crack locations in numerous images, the team innovated a user-friendly technology. Initially, they used a crack positioning method on a 3D site model, which involved extra aerial photography and model creation, consuming over a day.

This approach was impractical for urgent on-site needs related to crack detection. Therefore, the team abandoned the 3D method in favor of a more efficient technique, displaying crack positions on elevation views by unit. This adjustment significantly sped up the process of investigating cracks and deriving results. For a conventional multi-story residential complex of about 25 floors, typically, image stitching* of more than 300 front-view images is required to secure a photo overlap rate above 50%. By employing the POS-VISION technique, marking crack positions on elevation views is achievable without the need for overlapping images. This method decreases the total number of required images by over 40% and greatly diminishes the time spent on post-processing.

*Image Stitching: This technique combines several images to create a single panoramic photo.

▲Elevation view showing crack display (left) and another elevation view enhanced with a heat map for improved crack visualization.

POS-VISION has enhanced user convenience by implementing heat maps* based on the volume of crack occurrences, helping users quickly pinpoint areas needing urgent inspection. This method assigns different colors to each segment according to the severity of the cracks. Previously, crack detection images and occurrence counts were displayed on the site elevation view, offering users the option to click on images for more detailed information. However, the increase in crack data made this process cumbersome. The adoption of heat maps solved this problem by facilitating the efficient management of data and accentuating critical areas, even with the proliferation of data. This modification has been well-received in the field for its notable improvement in efficiency.

*Heat map: This visualization tool uses color coding—red to indicate areas requiring review and green for areas without issues—to assist users in easily identifying sections needing attention.

▲Crack images analyzed by POS-VISION on exterior walls.

POS-VISION has been utilized across nine sites involving 41 concrete structures, which include 39 buildings at seven construction sites, bridge slabs at one infrastructure site, and a coal storage facility at a single plant site. Having captured 24,641 images, the system has effectively identified cracks in areas that were challenging to detect before, thereby markedly enhancing construction quality at POSCO E&C.

The launch of POS-VISION has successfully addressed the oversight issues in managing the quality of building exteriors. This technology, suitable for various structures such as residential complexes, bridges, and highways, enables crack detection in areas difficult for humans to reach, thereby preventing potential risks ahead of time. Looking forward, POS-VISION aims to widen its scope and act as a “third eye” in identifying and mending quality issues in welding among other sectors.

POSCO E&C is advancing the development of autonomous flying drones to enhance the reach and efficacy of POS-VISION. Equipped with autonomous image-capturing capabilities, this technology promises to expand to more sites and boost operational efficiency. Moreover, employing autonomous drones equipped with vision sensors might solve the limitations associated with indoor crack detection and human errors. POSCO E&C is dedicated to maintaining quality and safety on-site through continued technological advancements and venturing into new domains.