Embed Size (px)
Citation preview
Keeping Your Process at the Centreof Everything We Do
1
DRIVING PERFORMANCE
Process Automation Specialists
Process Engineering Services
Level 1 Process Control Systems
Level 2 / 3 Solutions
optimAl process technology ltd.
2
Keeping Your Process at the Centre of Everything We Do
Process Engineering Services
3
Control system performance analysisBespoke controller designsControl system optimisationMill vibration analysis
Specialists in Machine Dynamics & Control
Comprehensive set of dynamic mill models - the basis for the delivery of a range of services
Process Engineering Services
4
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
WORK ROLL CHOCKWORK ROLL CHOCK
BACKUP ROLL CHOCK
BACKUP ROLL CHOCK
BACKUP ROLL CHOCKBACKUP 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
WORK ROLL CHOCKWORK ROLL CHOCK
WORK ROLL CHOCKWORK ROLL CHOCK
BACKUP ROLL CHOCK
BACKUP ROLL CHOCK
BACKUP ROLL CHOCKBACKUP ROLL CHOCK
BACKUP ROLL CHOCKBACKUP 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
Exit Gauge Measurement
CONTROLLER
Speed increase 25%
Gauge improvement > 20%
From mill audits through controller design to full optimisation
Model based controller designModel based optimisationImplementation on existing platformsHot millsTandem cold millsSingle stand cold & foil mills
Gauge Control Flatness Control ProductivityProcess Control Audits
Process Engineering Services
5
Instrumentation Design Services
Mill Duty Position Transducers
Standard optimAl productSony MagnescalesRobust & ultra low friction housing designRange of strokes availableFully assembled, tested & certificated
Mounting tool providedfor long stroke transducers
Fully tested on our specialised rig and certifiedRange of strokes available
Process Engineering Services
6
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 RollingModule 2: Rolling Mill Equipment and OperationModule 3: Measurement and Control of Strip ThicknessModule 4: Measurement and Control of Strip Flatness
Flatness simulation
Gauge simulation
Fully documentedCourse assessments & certification
Operator & Technician Level
Introduction to roll bite mechanicsRolling mill dynamicsAutomatic gauge controlSingle stand cold millsFoil millsTandem millsAutomatic flatness controlPractical simulations using optimAl dynamic models
Specialist Process Engineering
Process Engineering Services
7
Keeping Your Process at the Centre of Everything We Do
Level 1 Process Control Systems
Level 1 Process Control Systems
8
Controller design & optimisation using optimAl dynamic models
Systems platform selection based on customer requirementsABBGESiemens
Single stand cold & foil mill AGC & AFC
Full tandem cold mill solutionsAGCAFCInterstand tension control
Hot rolling mill HGC & AGC
Our focus is your process performance
KEEPING YOUR PROCESS AT THE CENTRE OF EVERYTHING WE DO
Level 1 Process Control Systems
9
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
Exit Gauge Measurement
MEASUREMENT
0
Exit GaugeReference
ExitGauge
Exit GaugeMeasurement
Exit Gauge( Microns )
[Time,EntryGauge]
Entry Gauge
Entry Gauge( Microns )
Exit Gauge Reference
Exit Gauge Measurement
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 ControlsMill Stand Controls (HGC)Automatic Gauge Control (AGC)Interstand Tension Control (ITC)Mill sequencing
Extensive engineering toolsDynamic controller testingFast fault findingSimple tuning interfaces
ABB Systems PlatformAC800 PEC Controller800xA programming
Advanced Tuning Techniques Outstanding Results
2 Stand Tandem Mill Process Control
• Full mill dynamic models• Adapted to fit your mill
Level 1 Process Control Systems
10
Total Process Support Outstanding Results
3 Stand Cold Tandem Mill Flatness Control
Our focus was final delivered productOn line system tuned to deliver required off line flatnessFull support from optimAl from cold mill through to slitteroptiMize flatness process diagnostics
Mill widening project – to accommodate 14 out can stockNew flatness controller requiredGE Rx7i platform – customer requirement
Proficy machine edition programmingCimplicity HMI
Full AFC solutionAir bearing shapemeter interfaceRoll bend and steer controlSpray control
Top flatness rating from can manufacturersTuning Analysis Assessment
Level 1 Process Control systems
11
Extensive Engineering Interfaces Level 2 from optimAl
3 Stand Cold Tandem Mill Process Control
Major mill revamp – extension from 2 to 3 standsCan stock productionGE Rx7i platform – customer requirementTotal process control solution
Mill stand controls Interstand tension controlMulti stand AGCAFC
Level 2 also supplied by optimAlStandard GE Programming Tools
Proficy machine edition Cimplicity HMI
Easy to use interfaces for tuning and maintenanceExtensive controller testing facilitiesDesigned for process & plant engineers
Process Diagnostics Mill Set Up
Level 1 Process Control Systems
12
Fully Integrated Approach Outstanding Results
1 + 1 Hot Line – HGC / AGC
Reversing breakdown hot millTwin coiler finishing hot millSupplied Controls:
Gap referencing for screwdown and hydraulic cylindersHydraulic Gap ControlAutomatic Gauge Control
GaugemeterSmith predictor feedback
Spray Control
ABB Systems PlatformAC800 PEC Controller800xA programming
High productivityHigh AccuracyLevel 2 supplied by optimAl
Fully integrated project with drives supplierCommon hardware and software platformClose co-operation on complete line sequencing
Level 1 Process Control Systems
13
Keeping Your Process at the Centre of Everything We Do
Level 2 / 3 Solutions
14
Machine Setup
Process Diagnostics
MES
Plant Production System InterfacesScheduling Coil Storage
MES
Reporting
Suite of Level 2 & 3 systems from machine setup through to ERP interfacing
ERP
Level 2 / 3 Solutions
15
Automatic Process Diagnostics for Metals Rolling & Processing
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
Level 2 / 3 Solutions
16
Casting Furnaces Hot Mills Cold Mills Foil Mills Levelling Lines Coating Lines Slitting Lines Testing
Casting FinishingAutomatic tracking of material & machine performance throughout the entire process
Hot SlittingCold & Foil
Advanced Machine Set Up Systems (AMSU)Rolling Finishing
Fixed and Adaptive Setup SystemsSame core system configured for specific machines
Hot rolling linesSingle stand and tandem cold millsSlitting lines
Highly configurableSetup managementInterfacing to control systemsInterfacing to plant scheduling systems
Multiple language support
Level 2 / 3 Solutions
17
Cold Mill Adaptive Setup
Customised Learning Strategies Outstanding Results
New approach to adaptive set upLower cost compared to full model based systemsInstalled systems
Single stand cold millTandem cold mill
Same core system as fixed set upHighly configurableMix of fixed and adapted set up data
Reduced head end scrapImproved yieldReduced threading time
Before After
Developed to fit your processDirect learning from measured dataoptimAl support for integration with your level 1 systems
Learned Rolling Force Learned Roll Bend
Level 2 / 3 Solutions
18
1 + 1 Hot Line – Level 2 – Line Tracking & Mill Set Up
Automatic Process Diagnostics Outstanding Results
Reversing breakdown hot millTwin coiler finishing hot millLevel 2 scope of supply
Line trackingMachine trackingScheduling interfaceQueue managementFixed setup
High productivityHigh Accuracy
optiMize process diagnostics for hot millsAutomated performance monitoringDetailed process analysis toolsWeb based production reporting
Level 2 / 3 Solutions
19
Keeping Your Process at the Centre of Everything We Do
25
