AFC Operators Manual · 2019-04-04 · AFC Operator Display..... 3-1 3.1. Overview ... that the reader has some knowledge of the operation of a paper machine and a basic understanding

MetalsMaster

AFC Operators Manual 6510020338 Rev 03

AFC Operators Manual

March, 2019

Confidentiality Statement

This manual is a product of Honeywell. It is intended for use only by Honeywell and customer personnel in connection with Honeywell products. It is strictly prohibited to copy this manual or any part thereof or to transfer this manual or any part thereof to any non-Honeywell person or entity, except customer personnel for use in connection with Honeywell products. Persons employed by a third-party service company shall not have access to this manual.

Notice

All information and specifications contained in this manual have been carefully researched and prepared according to the best efforts of Honeywell, and are believed to be true and correct as of the time of this printing. However, due to continued efforts in product improvement, we reserve the right to make changes at any time without notice.

Trademarks

All trademarks and registered trademarks are the properties of their respective holders.

Copyright

© 2019 Honeywell International Sàrl

All rights reserved. No part of this publication may be reproduced or translated, stored in a database or retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Honeywell.

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Table of Contents

Introduction ................................................................................................................................................v Audience ..................................................................................................................................................v About This Manual ................................................................................................................................ vi Related Reading ..................................................................................................................................... vi Conventions ........................................................................................................................................... vi

1. System Description ............................................................................................................................ 1-1 1.1. Overview ................................................................................................................................... 1-1 1.2. Operator station ......................................................................................................................... 1-1 1.3. AFC controller .......................................................................................................................... 1-1

2. Getting Started .................................................................................................................................. 2-1 2.1. Overview ................................................................................................................................... 2-1 2.2. System Architecture .................................................................................................................. 2-1 2.3. Metals AFC User Interface Layout ........................................................................................... 2-2

2.3.1. Page Layout ................................................................................................................... 2-3 2.3.2. Toolbar .......................................................................................................................... 2-4

3. AFC Operator Display ...................................................................................................................... 3-1 3.1. Overview ................................................................................................................................... 3-1 3.2. Flatness Control ........................................................................................................................ 3-1

3.2.1. Profile Graph ................................................................................................................. 3-3 3.2.1.1. Crown ....................................................................................................................... 3-3

3.2.2. Actuator Graph .............................................................................................................. 3-4 3.2.2.1. Zone Auto\Manual Status ......................................................................................... 3-4 3.2.2.2. AFC ON ................................................................................................................... 3-5 3.2.2.3. WarmUp Mode ......................................................................................................... 3-6 3.2.2.4. Edge Sprays Display................................................................................................. 3-6 3.2.2.5. Nozzle Test Mode .................................................................................................... 3-6

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3.2.3. Target Coolant Flow ..................................................................................................... 3-7 3.2.3.1. Cursor Buttons ......................................................................................................... 3-9 3.2.3.2. Flat ........................................................................................................................... 3-9

3.2.4. Secondary Displays ....................................................................................................... 3-9 3.2.4.1. WarmUp Pattern Setup Display ............................................................................. 3-10 3.2.4.2. Spray Pattern .......................................................................................................... 3-10 3.2.4.3. Backup Roll Sprays ................................................................................................ 3-12

3.2.5. Optimization ............................................................................................................... 3-12 3.2.6. Shapemeter and Tucking Roll Diagnostics ................................................................. 3-13

3.2.6.1. Tucking Roll Control ............................................................................................. 3-13 3.2.6.2. Shapemeter Diagnostic .......................................................................................... 3-14 3.2.6.3. Rotor Diaganostics ................................................................................................. 3-16

3.3. Mill Diagnostics Display ........................................................................................................ 3-17

4. Glossary.............................................................................................................................................. 4-1

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List of Figures Figure 2-1 Overview of AFC Architecture .............................................................................................. 2-2 Figure 2-2 User Interface Layout ............................................................................................................. 2-3 Figure 3-1 Flatness Display ...................................................................................................................... 3-2 Figure 3-2 Profile Graph .......................................................................................................................... 3-3 Figure 3-3 Crown ..................................................................................................................................... 3-3 Figure 3-4 Actuator Graph ....................................................................................................................... 3-4 Figure 3-5 Zone Auto\Manual Status ....................................................................................................... 3-4 Figure 3-6 AFC ON ................................................................................................................................. 3-5 Figure 3-7 Target Flow ............................................................................................................................ 3-7 Figure 3-8 Secondary Displays ................................................................................................................ 3-9 Figure 3-9 Warmup Pattern Setup.......................................................................................................... 3-10 Figure 3-10 Spray Pattern Setup ............................................................................................................ 3-11 Figure 3-11 Spray Patterns ..................................................................................................................... 3-11 Figure 3-12 Optimization ....................................................................................................................... 3-12 Figure 3-13 Mill Diagnostics Button ..................................................................................................... 3-17

List of Tables Table 2-1 Toolbar ..................................................................................................................................... 2-4

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Introduction

The Honeywell MXProLine™ system provides superior measurement and control system. This manual focuses on the MetalsMaster system designed to realize automatic flatness control (AFC) for aluminum rolling mill.

MetalsMaster can work for various rolling mills. MetalsMaster not only handles AFC supervise control loop but also handles the basic DDC control loop functions.

This manual documents the functions and operational process of the MetalsMaster for AFC.

The MetalsMaster manual series also includes the MetalsAFC R100 Engineer Manual, p/n 6510020337. The Engineer manual illustrates the engineer’s displays, such as system settings displays and parameter tuning displays.

Audience This manual is intended for use by engineers or process engineers and assumes that the reader has some knowledge of the operation of a paper machine and a basic understanding of mechanical, electrical and computer software concepts.

AFC Operators Manual Introduction

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About This Manual This manual contains three chapters and a glossary.

Chapter 1, System Description, provides an overview of the system.

Chapter 2, Getting Started, describes the system architecture, user interface layout of Metals AFC

Chapter 3, AFC Operator Display, provides an overview and description of the AFC operator display.

Chapter 4, Glossary

, provides the definition of the terms and acronyms used in this manual.

Related Reading The following documents contain related reading material:

Honeywell P/N Document Title / Description 6510020336 MetalsMaster AFC Technical Reference Manual 6510020337 MetalsMaster AFC Engineers Manual 6510020271 MetalsMaster Installation and Configuration Manual

Conventions The following conventions are used in this manual:

Text may appear in uppercase or lowercase except as specified in these conventions. Boldface Boldface characters in this special type indicate your input. Special Type Characters in this special type that are not boldfaced indicate system prompts,

responses, messages, or characters that appear on displays, keypads, or as menu selections.

Introduction Conventions

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Italics In a command line or error message, words and numbers shown in italics represent filenames, words, or numbers that can vary; for example, filename represents any filename. In text, words shown in italics are manual titles, key terms, notes, cautions, or warnings.

Boldface Boldface characters in this special type indicate button names, button menus, fields on a display, parameters, or commands that must be entered exactly as they appear.

Lowercase In an error message, words in lowercase are filenames or words that can vary. In a command line, words in lowercase indicate variable input.

Type Type means to type the text on a keypad or keyboard. Press Press means to press a key or a button. [ENTER] or [RETURN]

[ENTER] is the key you press to enter characters or commands into the system, or to accept a default option. In a command line, square brackets are included; for example: SXDEF 1 [ENTER]

[CTRL] [CTRL] is the key you press simultaneously with another key. This key is called different names on different systems; for example, [CONTROL], or [CTL].

[KEY-1]-KEY-2 Connected keys indicate that you must press the keys simultaneously; for example, [CTRL]-C.

Click Click means to position the mouse pointer on an item, then quickly depress and release the mouse button. This action highlights or selects, the item clicked.

Double-click Double-click means to position the mouse pointer on an item, and then click the item twice in rapid succession. This action selects the item double-clicked.

Drag X Drag X means to move the mouse pointer to X, then press the mouse button and hold it down, while keeping the button down, move the mouse pointer.

Press X Press X means to move the mouse pointer to the X button, then press the mouse button and hold it down.

The attention icon appears beside a note box containing information that is important.

The caution icon appears beside a note box containing information that cautions you about potential equipment or material damage.

The warning icon appears beside a note box containing information that warns you about potential bodily harm or catastrophic equipment damage.

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1. System Description

1.1. Overview The Honeywell MXProLine™ Automatic Flatness Control (AFC) system consists of the following hardware:

• Honeywell MXProLine™ Server

• Honeywell AFC Controller (NI PXI Real Time Platform, and ML200 platform)

• Honeywell MXProLine™ Operator Station (optional)

1.2. Operator station The operator station is desktop computer, with non- touch or touch screen monitor, UPS, keyboard, mouse and network card. MXProLine™ Base Software with Experion and RAE software loaded on this machine.

1.3. AFC controller The AFC controller consists of an NI PXI controller for the Mill Controls, and the MasterLogic 200 remote IO hardware for the Spray Controls and to read the Shape Roll readings. For hardware details, see MetalsMaster PXI, Installation and Configuration Manual, Honeywell P/N 6510020271.

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2. Getting Started

2.1. Overview This chapter describes the system architecture, user interface layout of Metals AFC.

2.2. System Architecture Figure 2-1 provides an overview of the system architecture for the MetalsMaster AFC for Aluminum Rolling.

AFC Operators Manual Getting Started

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Figure 2-1 Overview of AFC Architecture

2.3. Metals AFC User Interface Layout Figure 2-2 provides an overview of the user interface of Metals AFC which consists most of the displays an operator use.

The User Interface is categorized into following:

• Flatness Control

• Mill Controls

Getting Started Metals AFC User Interface Layout

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Figure 2-2 User Interface Layout

2.3.1. Page Layout Every display in MXProLine™ MetalsMaster is divided into following areas:

• Toolbar: The series of buttons that provide access to the operation functions and configuration displays.

• Navigation bar: The group of buttons (shift between the groups using the up arrow button at the right end of the bar) that opens all the displays.

• Status Line: The panel that displays system status, such as time, date and alarm status.

• Application Status Zone: The panel that displays the working status, such as coil start/end and the status of devices.

AFC Operators Manual Getting Started

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2.3.2. Toolbar The buttons on the toolbar provide quick access to the displays. The default configuration provides you with access to important displays and controls. See Table 2-1 for toolbar descriptions.

Table 2-1 Toolbar

Button Description

The System Menu button opens the System Menu.

The Alarm Summary button opens the Alarm Summary display.

The Acknowledge Alarm button acknowledges the most recent or selected alarm.

The Associated Display button opens the alarm associated with an object or the selected object.

Navigates to the requested/entered display.

When configuring the system, Engineers usually link related displays in a chain to view them in a sequence. Page Up opens the previous display in the chain. Page Down opens the next display in the chain.

Navigate Back and Navigate Forward buttons enable you to move backwards and forwards through displays. The Navigate Back button also contains a short History menu of previously viewed pages.

Reload Display reloads the current display.

Print Screen prints the current display. This provides a bitmap copy of the desktop and prints to the default printer. The output also displays the contents of any dialog boxes and the Station framework.

System Setup opens the System Setup and Debug display. This option is not accessible to Operators. Refer to Engineer’s Manual for more information.

Getting Started Metals AFC User Interface Layout

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Operation Adjustment opens the operation adjustments display.

Operator Mill Setup opens the operator’s mill setup display.

Mini-Profile opens the Mini-Profile dialog box.

Mini-Trend opens the Mini-Trend dialog box.

The Scan button moves the sensor to an Onsheet status.

Scanner Control opens the C-Frame Control display.

Offsheet moves the sensor to an Offsheet status.

About Station opens a display listing version and copyright information.

Help opens the Help file.

Exit Station exits the station.

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3. AFC Operator Display

3.1. Overview Following is the operator Display for flatness control:

• Flatness Control

3.2. Flatness Control Figure 3-1 displays some of the key parameters of the mill in the Flatness Control display.

AFC Operators Manual AFC Operator Display

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Figure 3-1 Flatness Display

AFC Operator Display Flatness Control

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3.2.1. Profile Graph

Figure 3-2 Profile Graph

The graph displays the deviation of the strain from the strain average and the deviation of the target profile from the target average across the sheet. The Profile is displayed or updated when the Shape is Onsheet. This display shows the 2-sigma of the strain profile.

3.2.1.1. Crown

This is the shape target amplitude in I-Units of the target profile.

Figure 3-3 Crown


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3.2.2. Actuator Graph

Figure 3-4 Actuator Graph

The Actuator Graph displays the calculated or manually entered duty cycle of each of the Work Roll Spray Zones.

• Manual: If checked, all the zones covered by the sheet are forced immediately to manual mode and the button automatically disables / unchecks. This is disabled when Spray Control is ON.

• Auto: If checked, all the zones covered by the sheet are forced immediately to automatic mode.

3.2.2.1. Zone Auto\Manual Status

Figure 3-5 Zone Auto\Manual Status

This display shows the status of each of the work roll zones.

Indicator Color Status Yellow The Work Roll Zone is ON / enabled.

The Work Roll Zone is under profile control and the Duty Cycle for the zone is calculated by the Profiule Control. The zone is Auto Control mode.


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Green The Work Roll Zone is OFF / disabled. The zone is in Manual Control mode.

When the Spray Control is turned On (AFC ON),all the work roll zones that are covered by the Sheet are automatically turned to Auto-control.

During the control, the user can always turn the Work Roll Zone to manual to enter a fixed duty cycle setpoint.

To enter a manual setpoint:

1. Click in the graph to the corresponding Work Roll Zone.

2. Click the Setpoint button on the right side of the graph.

3. Enter the Setpoint for zone in the Setpoint Entry popup.

4. The Setpoint Entry is not allowed for the zones outside the sheet width.

3.2.2.2. AFC ON

Figure 3-6 AFC ON

This button allows the user to enable the AFC Control. When the shape is Onsheet and the Spray Control is ready, this video request automatically enables the profile control. The Spray nozzle setpoints are calculated by the Profile control and the Spray status turns to cascade. This button is enabled only after the Coil is loaded.

The bottom section of the Operators display is divided into following and are available in Setup tab of the display:

• WarmUp

• Nozzle Test

• Edge Sprays


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3.2.2.3. WarmUp Mode

The WarmUp mode has the following functionality:

• Warmup ON: Video Request for Warmup mode. This can only be enabled if the Nozzle Test-Ready condition exists.

• Pattern: Enter the pattern number in this field to select the pattern for the Warmup mode. The pattern can be edited in the Warmup Pattern display. The selected pattern is loaded as the Spray Nozzle Setpoints when the Warmup mode Video Request is activated.

3.2.2.4. Edge Sprays Display

The Edge Spray display consists of the following functionality:

• Edge Nozzle: Edge Nozzles are the nozzles covered by inactive zones (zones outside the sheet width). A maximum of five zones are allowed. The edge nozzles outside the sheet width can be operated manually. The setpoint for the edge zone can be entered from the Setpoint display.

• Edge Override: Edge Override nozzles are the nozzles inside the sheet that do not participate in the Profile control. These zones are forced to stay in manual mode. The setpoint for these zones can be entered from Setpoint display.

3.2.2.5. Nozzle Test Mode

The Nozzle Test mode consists of the following functionalities:

• Nozzle Test: Video Request for Nozzle Test. This functionality is enabled when the AFC is in manual mode, both the cones are OUT and


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there is No Payoff/Rewind Tensions established and Spray PLC is OK.

• Test All: When the Nozzle Test Video Request is ON, and Test ALL is unselected, then only one nozzle is tested at a time.

Move the cursor to the zone that requires the test and then select the video request, if Test All is selected, then all the nozzles are forced to open Zone-by-Zone. The Duty Cycle for the Zone Under Test during the Spray Nozzle test is displayed\ in the Flatness Setup display.

3.2.3. Target Coolant Flow

Figure 3-7 Target Flow


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In the Target Coolant Flow section, you can view and enter the details for the following:

• Coolant flow: It is the default target flow (setpoint) for all the Spray zones in manual mode.

• Setpoint: Opens up the Setpoint Entry display. The setpoint for the selected spray zone (at the cursor position) can be entered in the following panel.


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3.2.3.1. Cursor Buttons

Moves the cursor 10 zones to the left.

Moves the cursor 1 zone to the left.

Moves the cursor 1 zone to the right.

Moves the cursor 10 zones to the right.

3.2.3.2. Flat

Initializes all the Manual active Spray zones to the Target setpoint. This functionality is disabled if the nozzle test conditions are ready or if the Spray Control is ON (AFC ON).

indicates the cursor selected spray zone.

3.2.4. Secondary Displays

Figure 3-8 Secondary Displays


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This display allows you to open the following secondary displays.

• WarmUp Pattern

• Spray Pattern

3.2.4.1. WarmUp Pattern Setup Display

WarmUp Patterns are stored in the system. When a Pattern Video Request is enabled on the Flatness control display, the selected pattern is loaded as the Profile setpoints. Usually, this mode is selected if the mill is stopped for an extended period of time or after a Roll Change.

• Copy actual: This copies the existing setpoint profile in the mill to this pattern.

Three patterns are allowed for the Work Roll and can be selected from the dropdown menu in the display. Only one pattern is allowed for the Backup roll.

The graphs display the selected warmup patterns for the Work Roll and the Backup roll. These patterns are applicable only for work rolls.

Figure 3-9 Warmup Pattern Setup

3.2.4.2. Spray Pattern

The Spray Pattern Setup display allows the user to setup the Coil Start and Coil End patterns. The graph displays the desired actuator setpoint array when in the


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selected pattern. This can be a single value or an array if some non-flat actuator array is required.

Figure 3-10 Spray Pattern Setup

The dropdown menu allows the user to select / edit one of the available patterns:

• Coil Start: Is automatically loaded into the Spray Setpoints array when the Coil Start condition is detected (Pattern 1 to 15 is for Coil Start).

• Coil Stop: Is automatically loaded into the Spray Setpoints array when the Coil Stop condition is detected.

Figure 3-11 Spray Patterns

C B, Krishna

New Image

C B, Krishna

Old Image, need to check with dattaraj


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3.2.4.3. Backup Roll Sprays

Use these options to manually turn ON/OFF Backup Roll Sprays.

• Backup Roll Sprays: Individually, turn ON / OFF each Backup Roll Spray.

3.2.5. Optimization

Figure 3-12 Optimization

The Optimization parameter provides the Spray Optimization Request. This function is only available when the AFC ON is turned ON. When this button is enabled/ON, then the tilt and bend mid range corrections are applied to the spray profile.


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3.2.6. Shapemeter and Tucking Roll Diagnostics

3.2.6.1. Tucking Roll Control

• Speed > Thread: Indicator turns green if the Speed is greater than the Thread Speed.

• Tension ON: Indicator turns green if tension is established.

• Cones In: Indicator turns green if the Payoff and Rewind Cones are in.

• No Strip Break: Indicator turns green if there is no strip break.

• Shapemeter Healthy: Indicator turns green if Shapemeter is healthy.


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• Tucking Roll Auto: Indicator turns green if Tucking Roll is in Automatic mode.

• Tucking Roll Manual Lower: Indicator turns green if Tucking Roll is in Manual mode and in a Lower position.

• Tucking Roll Manual Raise: Indicator turns green if Tucking Roll is in Manual mode and in a Raised position.

3.2.6.2. Shapemeter Diagnostic

Diagnostics Tab:

• Standardization: Used to standrize the shape roll if all the conditions are satisfied.

• Air Dryer Healthy: Indicator turns green if the Air Dryer is healthy.

• Transducer Input Status: Indicator turns green if the Air Dryer is healthy.

• Rotor Load High Status: Indicator turns green if all the individual rotor value is less than Rotor High Load Limit, which is available in Flatness Setup display.


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• Shapemeter protection level 2 status: Indicator turns green if Air Dryer Healthy, Transducer Input Status and Rotor Load High Status is green (healthy).

• Arbor Air Pressure: The numeric indicator displays the process value and minimum value in the bar. When the PV decreases to less than the minimum value, the indicator starts blinking an alarm.

• Thrust Air Pressure: The numeric indicator displays the process value and minimum value in the bar. When the PV decreases to less than the minimum value, indicator starts blinking an alarm.

• Rotor Overload Status: Indicator turns green if all individual rotors are healthy.

• Shapemeter protection level 3 status: Indicator turns green if Arbor Air Pressure, Thrust Air Pressure and Rotor Overload Status is green (healthy).

Wago Profibus IO Tab:

• Air Dryer Healthy: Indicator turns green if the Air Dryer is healthy.


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• Calibration Request: Indicator turns green when calibration request is ON.

• Calibration Abort: Indicator turns green when calibration abort request is ON

• Calibration Acknowledge: Indicator turns green when calibration request is accepted.

• Inc Calib Counter: Indicator turns green when there is increment in calibration count.

• Reset Calib Counter: Indicator turns green when calibration counter is reset.

• High Wrap: Indicator turns green when wrap angle changes from low to high.

3.2.6.3. Rotor Diaganostics

• No-Load Alarm: Indicator turns green if there is no load on the rotor.

• Transducer Alarm: Indicator turns green if there is no transducer alarm.

• Rotor High Load: Indicator turns green if all the rotor values are less than Rotor High Load limit which is configured in the Flatness Setup display.

• Rotor Overload Status: Indicator turns green if all the rotor values are less than Rotor Over Load limit which is configured in the Flatness Setup display.

AFC Operator Display Mill Diagnostics Display

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3.3. Mill Diagnostics Display

Figure 3-13 Mill Diagnostics Button

Click Mill Diagnostics as displayed in Figure 3-13 to open the Mill Diagnostics display. This display provides the status of parameters and the logic behind each of them.

Click the required parameter which are listed in the Flatness Control, the detailed diagnostic will be displayed on the right side of the display. All these indicators are updated in real-time.

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4. Glossary

AFC Automatic Flatness Control Cross direction control of sheet thickness in milling process

AGC Automatic Gauge Control Machine direction control of sheet thickness in milling process

ASD Auto Slow Down CD Cross Direction

Used to refer to those properties of a process measurement or control device that are determined by its position along a line that runs across the machine. The Cross Direction is transverse to the MD (Machine Direction) that relates to a position along the length of the machine.

C-Frame The C-shaped metal support for the sensor head. Code Code Name Another name for alloy

CRSP Continuous Real-time Sensor Processing Process by which a non-linear signal is converted into a linear signal.

DCS DDC

Distributed Control System Direct Digital Control PC based control where the PC acts as a controller i.e the control algorithm is executed in the PC which may be interfaced with an I/O system

DSR Data Storage and Retrieval A mechanism provided in RAE for storing recipe- or grade-dependent data, such as tuning, calibration and setup values, and retrieving them when a recipe is loaded. The recipe- or grade-dependent data are saved to a database known as the Recipes database.

Gauge Sheet thickness HMI Human Machine Interface

A graphical interface that displays process data and provides a means to edit control-related parameters.

MD Machine Direction The direction in which product travels down the machine.

AFC Operators Manual Glossary

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MIS Management Information System An application provided by RAE to accumulate and manipulate production data in order to generate reports for management purposes.

MXProLine™ MXProLine™system is a measurement and control solution designed for flat sheet applications in plastics, rubber, aluminum and non-woven processes

NI NI PXI RT

National Instrument PXI hardware and LabVIEW are products from National Instrument. RT stands for Real Time.

Permanents Database

A database provided by RAE to store the last values of certain process parameters so these values can be restored when the QCS starts up from a previous shutdown.

PXI PCI eXtensions for Instrumentation (PXI) A modular instrumentation platform designed for measurement and automation applications that require high-performance and a rugged industrial form-factor.

QCS Quality Control System A computer system that manages the quality of the product produced.

RAE Real-Time Application Environment The system software used by MXProLine™ and Da Vinci QCS to manage data exchange between applications

RTDR Real-Time Data Repository The real-time database managed by RAE to store system data and data for individual applications.

TAD Target Adaptive Control TG Target Gauge VIO Virtual Input/Output

Documents

AFC Operators Manual · 2019-04-04 · AFC Operator Display..... 3-1 3.1. Overview ... that the reader has some knowledge of the operation of a paper machine and a basic understanding