KEEPING YOUR PROCESS AT THE CENTRE OF EVERYTHING WE DO · ABB Systems Platform • AC800 PEC Controller • 800xA programming • High productivity • High Accuracy • Level 2 supplied

KEEPING YOUR PROCESS AT THE CENTRE OF EVERYTHING WE DO

DRIVING PERFORMANCE

PROCESS AUTOMATION SPECIALISTS

Process Engineering Services

Level 1 Process Control Systems

Level 2 / 3 Solutions



• Control system performance analysis • Bespoke controller designs • Control system optimisation • Mill vibration analysis

Specialists in Machine Dynamics and Control

Our comprehensive set of dynamic mill models is the basis for the delivery of a range of services


MAE WEST

BLOCK

MILL

HOUSING

MAE WEST

BLOCK

MILL

HOUSING

MAE WEST

BLOCK

MILL

HOUSING

MAE WEST

BLOCK

MILL

HOUSING

MILL

HOUSING

MAE WEST

BLOCK

MILL

HOUSING

MAE WEST

BLOCK

MILL

HOUSING

MILL

HOUSING

WORK ROLL CHOCK

WORK ROLL CHOCK

WORK ROLL CHOCKWORK ROLL CHOCK


BACKUP ROLL CHOCK

BACKUP ROLL CHOCK

BACKUP ROLL CHOCKBACKUP ROLL CHOCK


MAE WEST

BLOCK

MILL

HOUSING

MAE WEST

BLOCK

MILL

HOUSING

MAE WEST

BLOCK

MILL

HOUSING

MAE WEST

BLOCK

MILL

HOUSING

MILL

HOUSING

MAE WEST

BLOCK

MILL

HOUSING

MAE WEST

BLOCK

MILL

HOUSING

MILL

HOUSING

WORK ROLL CHOCK

WORK ROLL CHOCK



BACKUP ROLL CHOCK

BACKUP ROLL CHOCK



NEGATIVE

BEND SERVO

NEGATIVE

BEND SERVO

POSITIVE

BEND SERVO

POSITIVE

BEND SERVO

BEND CONTROLLERBEND CONTROLLER

MEASURED PRESSURESMEASURED PRESSURES

-VE BEND

SERVO DRIVE

-VE BEND

SERVO DRIVE

+VE BEND

SERVO DRIVE

+VE BEND

SERVO DRIVE

OPERATOR

ADJUSTMENTS

AFC

CORRECTIONS

OPERATOR

ADJUSTMENTS

AFC

CORRECTIONS

We specialise in the optimisation of mill control performance

Exit Gauge

TRANSPORT DELAY

Entry Gauge

Position Reference

ROLLING MILL

Exit Gauge Measurement

MEASUREMENT

0

Exit GaugeReference

ExitGauge

Exit GaugeMeasurement

Exit Gauge( Microns )

[Time,EntryGauge]

Entry Gauge

Entry Gauge( Microns )

Exit Gauge Reference


CONTROLLER

Speed increase 25%

Gauge improvement > 20%

From audits through controller design to full optimisation

• Model based controller design • Model based optimisation • Implementation on existing platforms • Single stand cold mills • Tandem cold mills • Hot mills

Gauge Control Flatness Control Productivity Process Control Audits


Instrumentation design services

Position Transducers

• Standard optimAl product • Sony Magnescales • Robust & ultra low friction housing design • Range of strokes available • Fully assembled, tested & certificated Mounting tool provided for long stroke transducers

Fully tested on our specialised rig and certified Range of strokes available


FLATNESS

THICKNESS

板形

厚度

FLATNESS

THICKNESS

板形

厚度

Ce rtific ate o f training

optimAloptimAl

This is to certify that

__________________

has successfully completed the 1 day training course:

Introduction to Cold Rolling of AluminiumIntroduction to Cold Rolling of Aluminium

for Operatorsfor Operators

Presented by:Presented by:

optimAL process technology limitedoptimAL process technology limited, January 2006 , January 2006

Course content:Course content:

Module I: Strip properties and the mechanics of rolling

Module II: Rolling equipment and operation

Module III: The measurement & control of the strip thickness

Module IV: The measurement & control of the strip flatness

____________________ Mattias Andersson ____________________ John Mason ___ January, 2006

optimAloptimAl

Process Training

• Module 1: Strip Properties and the Mechanics of Rolling • Module 2: Rolling Mill Equipment and Operation • Module 3: Measurement and Control of Strip Thickness • Module 4: Measurement and Control of Strip Flatness

Flatness simulation Gauge simulation

Fully documented Course assessments & certification

Operator & Technician Level

• Introduction to roll bite mechanics • Rolling mill dynamics • Automatic gauge control

• Single stand cold mills • Foil mills • Tandem mills

• Automatic flatness control • Practical simulations using optimAl dynamic models

Specialist Process Engineering


• Controller design & optimisation using optimAl dynamic models • Systems platform selection based on customer requirements

• ABB • GE • Siemens

• Single stand cold and foil mill AGC & AFC • Full tandem cold mill solutions

• AGC • AFC • Interstand tension control

• Hot rolling mill HGC & AGC

Our focus is your process performance



Bengt Jansson:

Granges Technical

Director:

The performance

of the cold tandem

mill is world class !

Commissioning

and achievement

of project target

was reached within

very short time !

Exit Gauge

TRANSPORT DELAY

Entry Gauge

Position Reference

ROLLING MILL


MEASUREMENT

0

Exit GaugeReference

ExitGauge

Exit GaugeMeasurement

Exit Gauge( Microns )

[Time,EntryGauge]

Entry Gauge

Entry Gauge( Microns )

Exit Gauge Reference


CONTROLLER

10-1

100

101

-15

-10

-5

0

5

dB

Stimulus --> Position Reference

10-1

100

101

-50

0

50

100

150

Frequency Hz

Deg

rees

• Supplied Controls: • Mill Stand Controls (HGC) • Automatic gauge control (AGC) • Interstand tension control (ITC) • Mill sequencing

• Extensive engineering tools • Dynamic controller testing • Fast fault finding • Simple tuning interfaces

ABB Systems Platform • AC800 PEC Controller • 800xA programming

Advanced Tuning Techniques Outstanding Results

2 Stand Tandem Mill Process Control

• Full mill dynamic models • Adapted to fit your mill


Total Process Support Outstanding Results

3 Stand Cold Mill Flatness Control

• Our focus was final delivered product • On line system tuned to deliver required off line flatness • Full support from optimAl from cold mill through to slitter • optiMize flatness process diagnostics

• Mill widening project – to accommodate 14 out can stock • New flatness controller required • GE Rx7i platform – customer requirement

• Proficy machine edition programming • Cimplicity HMI

• Full AFC solution • Air bearing shapemeter interface • Roll bend and steer control • Spray control


Top flatness rating from can manufacturers Tuning Analysis Assessment


Extensive Engineering Interfaces Level 2 from optimAl

3 Stand Tandem Mill Process Control

• Major mill revamp – extension from 2 to 3 stands • Can stock production • GE Rx7i platform – customer requirement • Total process control solution

• Mill stand controls • Interstand tension control • Multi stand AGC • AFC

• Level 2 also supplied by optimAl

• Standard GE Programming Tools • Proficy machine edition • Cimplicity HMI

• Easy to use interfaces for tuning and maintenance • Extensive controller testing facilities • Designed for process & plant engineers

Process Diagnostics Mill Set Up

Fully Integrated Approach Outstanding Results

1 + 1 Hot Line – HGC / AGC

• Reversing breakdown hot mill • Twin coiler finishing hot mill • Supplied Controls:

• Gap referencing for screwdown and hydraulic cylinders • Hydraulic Gap Control • Automatic Gauge Control

• Gaugemeter • Smith predictor feedback

• Spray Control

ABB Systems Platform • AC800 PEC Controller • 800xA programming

• High productivity • High Accuracy

• Level 2 supplied by optimAl • Fully integrated project with

drives supplier • Common hardware and software

platform • Close co-operation on complete

line sequencing


Machine Setup

Process Diagnostics

MES

Plant Production System Interfaces Scheduling Coil Storage

MES

Reporting

Suite of Level 2 & 3 systems from machine setup through to ERP interfacing

ERP


Automatic Process Diagnostics for Metals Rolling & Processing

Hot Slitting Levelling Coating Cold Foil

Tracking material and machine performance through the whole process Rolling Finishing

Production


ROI

$

¥

€

Reduced scrap

Increased yield

Increased productivity

Fast detection of process problems

Material and machine performance tracking

Better use of valued process engineering resources Delivering real payback

Plant Management & Supervision

Process Engineering & Quality Control

PLEASE ASK FOR A DEMONSTRATION AT OUR STAND

optiMize generates production reports to assist with tracking performance and identifying equipment issues. We use optiMize daily to produce SPC charts using the Group Statistics function. Process and electrical engineers use it for in depth problem analysis. The optiMize system has proven to be invaluable for identifying and controlling key process variables at our five stand tandem mill. Joey Bain, Five Stand Mill Superintendent


1 x Reversing Breakdown 1 x Intermediate Breakdown

1 x 4 Stand Finishing

Hot Rolling Cold Rolling Slitting

2 x Edge Slitting & Oiling

1 x 5 Stand Tandem 2 x 3 Stand Tandem

1 x Single Stand

Wise Alloys optiMize System

Coating

1 x Continuous Coating Line


Production management use the optiMize tools on a daily basis. The detailed web based production reports are projected in the morning meeting to identify key production and quality issues and to direct any necessary corrective actions.


optimAl process technology was originally commissioned to replace an existing gauge monitoring tool. The finished product far exceeded expectations when it was implemented back in 2007. Since then the system has been expanded to include key process variables, process evaluations, alarms/alerts and trending. The system is dynamic – if a variable (analog, digital or virtual signal) is captured it can be displayed and analyzed. Data storage and retrieval is fast and reliable. The real beauty of the optiMize system is with a ten minute demo anyone can begin to use the tool effectively to analyze data. Wise Alloys LLC has implemented optiMize throughout the plant and relies heavily on it to monitor and maintain product quality. It is an integral part of our Electronic Lot Ticket System and SAP Quality Module. Shelley Wolf, Senior Systems Engineer Wise Alloys LLC

optiMize incorporates tools to analyze the performance of key parameters from hot mill profile through cold mill gauge and flatness to coating line thickness and distribution.

Thickness Profile Analysis Gauge Analysis

optiMize is fully integrated to the plant quality systems, providing key feedback to the SAP quality module.


This is a powerful system which can provide us extensive tools for tracking the process, finding and solving process failures. This system improves my work efficiency and I use optiMize on a daily basis. It can search and track the coil through the whole process. By using different tools in the system, we can analyse gauge deviation issues and track the root cause. For process follow up, we can select some coils (filter by gauge/ alloy etc. wide range of criteria) produced in a certain period, then use the group statistics tool to monitor the trend and find if there are any problems, such as gauge performance, flatness performance, etc. We also use the alarm mail facility to create process/production alarms. optiMize will automatically send alarm emails to the related person if any key process values are out of control set point. Maria Dong, Process Department Gränges Shanghai

1 x Reversing Twin Coiler

Hot Rolling Cold Rolling Slitting

2 x Heavy Gauge 1 x Light Gauge (Loop) 4 x Light Gauge (Tight)

1 x 2 Stand Tandem 3 x Single Stand

PLANT TO PLANT BENCHMARKING

With optiMize installed at their plants in Sweden and China, Gränges can use the system to benchmark performance across the whole group and develop best practice.

Gränges Shanghai optiMize System

In order to meet their customer’s ever higher demands for quality and tighter tolerances Gränges use the optiMize suite of applications to track their process and evaluate coil quality.

Hot Slitting Cold & Foil

Advanced Machine Set Up Systems (AMSU) Rolling Finishing

• Fixed and Adaptive Setup Systems • Same core system configured for specific machines

• Hot rolling lines • Single stand and tandem cold mills • Slitting lines

• Highly configurable • Setup management • Interfacing to control systems • Interfacing to plant scheduling systems

• Multiple language support


Cold Mill Adaptive Setup

Customised Learning Strategies Outstanding Results

• New approach to adaptive set up • Lower cost compared to full model based systems • Installed systems

• Single stand cold mill • Tandem cold mill

• Same core system as fixed set up • Highly configurable • Mix of fixed and adapted set up data

• Reduced head end scrap • Improved yield • Reduced threading time

Before After

• Developed to fit your process • Direct learning from measured data • optimAl support for integration with

your level 1 systems

Learned Rolling Force Learned Roll Bend


1 + 1 Hot Line – Level 2 – Line Tracking & Mill Set Up

Automatic Process Diagnostics Outstanding Results

• Reversing breakdown hot mill • Twin coiler finishing hot mill • Level 2 scope of supply

• Line tracking • Machine tracking • Scheduling interface • Queue management • Fixed setup

• High productivity • High Accuracy

• optiMize process diagnostics for hot mills

• Automated performance monitoring • Detailed process analysis tools • Web based production reporting


Documents

KEEPING YOUR PROCESS AT THE CENTRE OF EVERYTHING WE DO · ABB Systems Platform • AC800 PEC Controller • 800xA programming • High productivity • High Accuracy • Level 2 supplied