Osborn Roller Catalogue

Innovative Solutions for Metals Processing Technology

Brush Rolls

Equipment & Systems

Non-woven Rolls

Members of Jason Finishing Group

umbruch_engl_deu:umbruch_deu 05.03.2009 15:07 Uhr Seite 1

With the ability to connect global competence

in the best possible way for our customers

alongside the provision of local, extensive

service, we develop and manufacture innova-

tive, quality products and solutions targeted

for machine system engineering and opera-

tors of rolling mills and strip processing line

technology.

Mission statement

1

Reliability and sustainability in terms of our

customers, employees and company deter-

mine our actions. At the same time, the prin-

ciple of responsible and careful management

of our environment and its natural resources

applies to us at all times.


Content

2

Introduction Page 3

Brush roll applications

2.1 Degreasing, washing and cleaning Page 5

2.2 Activation of strip surface Page 7

2.3 Roll cleaning and polishing Page 8

2.4 Strip polishing and finishing Page 9

2.5 Scale removal Page 11

2.6 Roll coating control Page 13

2.7 Transport roll systems for HHT furnaces Page 15

2.8 Transport roll systems for high temp applications Page 17

Brush roll systems

3.1 Complete brush roll systems Page 19

3.2 Factory Assembly (FA) brush roll systems, Integrated Maintenance Service Page 21

3.3 Customer Assembly (CA) brush roll systems Page 23

3.4 OSBORN HDL® brush rolls Page 25

3.5 Lipprite® abrasive non woven rolls Page 27

NOVOTEX® non-woven rolls Page 29

Innovative equipment technology

5.1 Vacuum squeezing systems Page 35

5.2 Brushing equipment for strip processing lines Page 37

Load Runners® idler rollers and load rails Page 39

Fill materials Page 41

1

2

3

4

5

6

7

Our further product range Page 459

2.9 Transport roll systems for noise reduction Page 18

Technical data Page 438


Europe

Asia Pacific

America

OSBORN InternationalYour competend partner in surface finishing solutions - worldwide

Companies all over the world rely on the quality and effi-ciency of OSBORN. With a total of twelve sites, high qualitytools are developed and manufactured for processing sur-faces for use in a variety of branches in industry.

Specialised technology centres in our factories in Germany,England, Sweden, the USA, Brazil and China as well as a

close complex service network of the other OSBORN busi-nesses and branch offices or local service partners provide acomprehensive service for our customers’ rollers anywherein the world.

OSBORN International GmbHRingstraße 1035099 Burgwald - GermanyPhone: ++49 (64 51) 5 88-0Fax: ++49 (64 51) 5 88-206eMail: [email protected]

OSBORN Unipol Ltd.Lower Church Street Chepstow, Monmouthshire NP16 5XT - UKPhone: ++44 (12 91) 63 40 00 Fax: ++44 (12 91) 63 40 98eMail: [email protected]

OSBORN International AB(Sinjet Nässjo Borst)Huskvarnavägen 105S-56123 Huskvarna - SwedenPhone: ++46 (36) 38 92 00 Fax: ++46 (36) 14 43 49eMail: [email protected]

OSBORN International Ltda.Rua Lemos Torres, 150, Jardim Galiardi09890-070 Sao Bernado do Campo - BrazilPhone: ++55 (11) 43 91 65 59Fax: ++55 (11) 43 91 65 50eMail: [email protected]

OSBORN International5401 Hamilton AvenueCleveland, OH 44114-3997 - USAPhone: ++1 (800) 720 33 58 Fax: ++1 (216) 361-1913eMail: [email protected]

OSBORN International ChinaRm. 505, Tower H, Huiyuan Int. ApartmentNo. 8 Beichen East Road, Chaonyang DistrictBeijing 100101 - PR ChinaPhone: ++86 (10) 84 98 81 91 Fax: ++86 (10) 64 99 18 63eMail: [email protected]

1

3

Brush roll service centers

Further contact details worldwide: www.metallurgy-brush.com

Brazil • China • Denmark • France • Germany • Great Britain • India • Mexico • Portugal • Romania • Spain • Sweden • USA


4

High-quality raw materials, years of experience, modernmanufacturing techniques and careful workmanship. Theseare important criteria which provide the consistently highquality of OSBORN products. Quality assurance accompaniesall stages of production. It is fully integrated into the process-es and certified in accordance with DIN EN ISO 9001-2000.This has made us the world’s Number 1 in brush technology,

but we are not satisfied with that. Constant innovation andproduct development are of central importance to us, both in-house and in close cooperation with technology partners inEurope, Asia and North America. We seize the incentive ofmaking our range of services, and with it the products andprocesses of our customers, better, faster, more reliable, saferand more environmentally friendly.



Degreasing, washing and cleaning

The demands relating to the quality and the technical prod-uct characteristics of flat rolled steel in the form of coldrolled steel, tin plated steel, electrical steel, galvanized stripsor other refined surface materials are steadily rising. Alongwith increasing processing speeds, the logical requirementfor optimising the tempering, refinement or coating processof the upstream strip cleaning section arises.

With the development and introduction of the HDL® brushroller, OSBORN has found an answer to this problem, which

in comparison to conventional brush rollers sets new stan-dards in the degreasing and cleaning of strip surfaces.Through the consistent further development of the mostimportant quality criteria (fill material, brush constructionand fill density) and at the same time by optimising theusing parameters, significant improvements can beachieved in terms of the brush lifetime / cleaning perform-ance and with it, apart from the technically qualitativeaspect, a reduction in operating and maintenance costs canalso be realised.

2.1

5

Application category Metallurgic field Process line Description of application OSBORN product range

Degreasing, washing

and cleaning

Carbon steel

Stainless steel

Aluminium

Non ferrous

CGL, CAL, CL/ DL, ETL

CCL, CAPL, BAL, CL

TLL, SL/ CCL

CL, DPL, APL, CPL

Removal of oil, grease, otherprotective coatings, rollingresidues or dirt from the

strip/sheet surface

Brush rolls, abrasive or non-abrasive, OSBORN HDL®

Technology

OSBORN HDL® - a new benchmark in strip cleaning

Different demands are made on the brush depending on thetype and degree of soiling of the primary material as well asthe strip cleanliness required for the subsequent processstep. While optimum degreasing and micro-cleaning can beachieved with non-abrasive multi-filaments, abrasive fila-ments are ideally suited for the removal of strongly adhesiverolling retentions from the previous rolling process.

OSBORN HDL® brush rollers are therefore individually tai-lored to the relevant case in hand. At the same time, multi-fil-aments and special mono-filaments can be used with or with-out an abrasive portion as single bristle or mixture filaments.


6

Besides brush rollers for degreasing and cleaning applica-tions, OSBORN offers a series of other innovative productsand solutions for cleaning sections of strip lines:

• LOAD RUNNERS® ensure a durable and maintenance-free function of roll exchange vehicles.

• Temperature and alkaline resistant brush sealing provides optimum splash protection on the strip inlet and outlet of individual machine elements.

• Vacuum squeezing systems set new standards in the com-plete drying of strip edges. It is possible to replace the hot air dryer altogether and through this, ensure enormous energy savings as well.

• In the modernisation of strip lines it is possible, through the integration of optimised brush machines instead of the old line, to create additional space for further improvements to the line due to the compact design as well as an improve-ment in cleaning efficiency.

• NOVOTEX® squeezing rollers complete the OSBORN strip cleaning range. Compared to conventional rubber or polyurethane rollers, these non-woven rolls offer a number of beneficial product characteristics, such as significantly better coefficients of friction, material compression or cut and wear resistance, which in turn ensures longer durabili-ty, improved squeezing results, the prevention of aquaplan-ing and the reduction of damage to the strip.

OSBORN innovations for cleaning sections in strip processing lines

Alkaline brush

cleaning

Squeezing

rolls

Brush cleaning Squeezing

rolls

Squeezing

rolls

Alkaline spray

cleaning

Electrolytic

cleaning

Water rinsing Hot air dryer

OSBORN HDL® NOVOTEX® NOVOTEX®OSBORN HDL® NOVOTEX®

Load Runners® Brush sealings



Activation of strip surface2.2

7


Activation of strip surface

Brush rolls, abrasive or wire-filled, OSBORN HDL®

Technology

The activation of the strip surface is an important task both inthe production of rolled claddings as well as in the coatingand/or finishing of strip steel, tinplate, electrical steel stripand other materials. In rolled cladding, the core and, if neces-sary, the overlay strips or plates have to be freed initially fromoil, grease, dirt, carbon particles and oxides with the help ofbrush rollers in alkaline cleaning or acidic pickling processes.

In the next process step, an activation of surfaces then takesplace by generating a defined roughness using abrasive orwire brushes. A similar process also happens in continuousstrip coating. In both cases, an optimal adhesion is guaran-teed for the subsequent rolled cladding and/or organic ormetallic coating through surface activation.

Strip surface activationprior to coating

Strip, sheet or plate surface preparation prior to cladding,

coating or pressing

Carbon steel

Aluminium

Non ferrous

CGL, CCL, EGL, ETL

CM

APL, CPL

OSBORN HDL® - micro cleaning plus surface activation

Here too, HDL® rollers from OSBORN create an ideal combi-nation of the different brush functions which are required. Thenon-abrasive multi-filaments ensure optimum micro-cleaningas the abrasive filament mechanically intensifies this throughits abrasive effect and at the same time, generates the surfaceactivation which is required. The grinding agent, grain size,facing density and abrasive portion are also individuallyadjusted to the respective individual application.

In steel sheet coating, the brush roller has long been promot-ed as an absolute high-performance and precision tool in thecase of thicknesses of <0.15mm, coating thicknesses of 0.05g/ m² and ever higher line speeds. At the same time, the indi-vidual demands made on the brush can be quite differentdepending on the flatness, surface hardness of the startingmaterial and the nature of the subsequent coating or plating.

This is a challenge that OSBORN has set itself for years andthrough which we have worked out a technological advan-tage for ourselves in the production of brush rollers with thedevelopment of innovative microfilaments and brush con-structions as well as even higher quality standards.



Roll cleaning and polishing 2.3

8


Roll cleaning and polishing

Carbon steel

Stainless steel

Aluminium

SPM, TM, CGL

SPM, TM

CRM

Removal of oxides, dirt and rolling residuals

Helimaster® Brush rolls, abr-sive or wire-filled; Non-abra-

sive Brush rolls; Lipprite®

abrasive non-woven rolls

Roll cleaning appliaction in a typical skin-pass mill

For cleaning work and back-up rolls in wet or dry operatedrolling and skin-pass mills, OSBORN’s Helimaster brushrollers have characterised worldwide technological develop-ment for decades, both in online lines integrated in strip linesas well as stand-alone off-line rolling stands.

In doing so, the rollers can work sporadically or continuous-ly, designed as a wire or an abrasive brush. Each brush is

neutrally ground at the radius and axially and either gains acylindrical camber ground, or for offsetting the computed rolldeflection, a positive and/or negative camber ground.

In the meantime, with Lipprite® abrasive rollers, an alternativetechnology has also been developed and manufactured in-house for skin-pass roller cleaning.

The brush roller itself is only part of the solution. This is because this technically demanding application can ultimately only be opti-mally implemented by a precise matching of the brush toolwith operational and process parameters. The reproducibilityof the specified corrosiveness and brush effect plays animportant role as well as constant tool performance from thefirst point of use to the exchanging of the roller.

For the cleaning of deflector, shape control or thickness meas-urement rolls, special wear-resistant non-abrasive plastic fila-ments are used. They ensure an equally thorough removal ofsolids and liquid materials without damaging the roll surfaceor altering the roughness. At the same time, the filament typeand bristle diameter are dependent on the surface hardnessand the degree of soiling of the roll to be cleaned.



Strip polishing and finishing2.4

9

When it comes to the optical finishing of strip surfaces inthe form of polishing, sanitising, finishing or decorativegrinding and brushing, you’re in good hands with OSBORN.Decades of experience in the machining of steel, stainlesssteel, aluminium or other non-ferrous surfaces have givenus a technological advantage, from which today our cus-tomers benfit worldwide.

Apart from high-quality wire and abrasive brushes, we canat the same time rely on the merger with the Lippert-UnipolGroup, one of the global leaders in abrasive and polishingtools, using polishing and abrasive rollers and polishingpastes on a selection and combination of tools and pro-cessing alternatives, which is unique in the market. Use thisadvantage to optimise your process - for perfect surface fin-ishing.


Strip polishing and finishing

Brush rolls abrasive or wire-filled; Bessemer-wire brush

rolls; OSBORN HDL®

Technology; Lipprite® abrasi-ve non-woven rolls; UNIPOL®

polishing emulsion

Carbon steel

Stainless steel

Aluminium

Non ferrous

PL, APL , FL

Oxide removal, polishingand finishing of hardened

and tempered stripsOxide removal, polishing,finishing and generating

decorative surfaces

Today, increasingly higher demands are made on the finalmachining of strips. Apart from an optically perfect and per-fectly homogeneous surface over an entire field of vision, thecorrection of small surface defects in the last mechanicalmachining step is demanded at the same time. This appliesequally to the operators of strip lines as well as for servicecentres or the direct processors of coils.

Different types of rollers and coatings can also be useddepending on the material type and quality, the surface hard-ness and the required finish and condition before the final fin-ishing. For determining the respective optimum tool, wecarry out individual pilot tests at test lines in our laboratory.


10

Lipprite® abrasive non woven rolls - for a perfect surface finish

A combination of Bessemer wire roller brushes and polishingemulsions are used in the removal of oxide layers and pol-ishing cold rolled uncovered strips after annealing re-crys-tallisation. At the same time, both components come fromOSBORN-UNIPOL and are specifically coordinated to the indi-vidual surface requirements.

Our Lipprite® product series represents an alternative tobrush rollers with a wire or abrasive bristle coating, as withgrinding non-woven rollers, an absolutely uniformed finefinal grind and a corresponding homogeneous surface finishcan be achieved. With the correct contact pressure, the flexi-ble roller surface is in a position similar to a brush, to offsetany slight unevenness of the strip.

UNIPOL® polishing emulsions are initially directly applied tothe strip surface to be processed as a liquid paste in immer-sion baths or by means of a low-pressure, medium-pressure,high-pressure or airless spraying system.With Bessemer wire measuring diameters of 0.06 or 0.08

mm, filled rollers serve as carriers of this paste in the subse-quent polishing process.

Polishing station with

Bessemer wire brush rolls

All-in-one solution made by OSBORN-UNIPOL

UNIPOL® polishing emulsion

(liquid emulsion application)



Scale removal

In de-scaling strip surfaces after the hot and cold mill process,our brush rollers have been setting standards in strip lines foryears. OSBORN’s developments and innovations both on thepart of brush construction as well as filaments have in themeantime set the international standards in annealing andpickling lines or bright annealing lines for stainless steel strip.

With the development of acid resistant fill materials it has

been possible to achieve tremendous quality and improve-ments relating to service life on numerous strip lines and withit, a substantial reduction in the total cost. The parallel opti-misation of the brush / shaft design and operational parame-ters through targeted assistance on site with the customer isanother important OSBORN competence based on our long-standing worldwide experience. Set us a challenge!

2.5

11


Scale removal

Carbon steel

Stainless steel

Non ferrous

CPL

HAPL

HAPL

HRM

Brush rolls abrasive or wire-filled; Heavy abrasive brush

rolls; OSBORN HDL®

Technology; Lipprite® abrasi-ve non-woven rolls

Heavy duty descaling prior to acid pickling

Heavy duty descaling between acid tanks

Scale and dirt removal prior to rolling

A new brush-generation - acid proof filaments

Through the development of special abrasive and non-abra-sive facing materials combined with a much improved levelof acid resistance and with that good wearing properties, thelifetime of brush rollers in stainless steel strip lines has nowbeen significantly increased. This allows tremendous costsavings in the form of longer lifetimes and lower mainte-nance costs.

Ideally, the abrasive rollers are inserted on roller systemsmade from hollow shafts with bore holes. Apart fromimproved cooling of the filaments in the continuous opera-tion of the roller, these also provide the continuous rinsing

out of acid or other corrosive media from the brush lining. Onthe one hand, an optimum rinse function is ensured by thecorrect number and size of the cooling holes and the other bythe correct choice concerning the quantity of liquid.

At the downstream strip drying operation, similarly signifi-cant process improvements and substantial cost savings canbe achieved through squeezing rollers using newly devel-oped acid-resistant non-woven materials as well as vacuumsystems.


12

In manufacturing stainless steel flat products, OSBORNInternational’s intelligent solutions and innovations play apart in process optimisation and quality improvement as wellas being deployed for de-scaling hot and cold mill strip sur-faces at many other levels of the value chain:

• HDL® brush rollers with a micro-fibre brush for careful and thorough cleaning of sensitive strip surfaces

• Acid and temperature resistant brush sealings

• Lipprite® abrasive rollers for surface finishing and follow-up processing plates and strips

• Braking, tension, deflection or pressure rollers made from a non-woven covering for replacing rubber or polyure-thane rollers

• NOVOTEX® squeezing rollers with an acid resistant non-woven covering

• Helimaster brush rollers for cleaning rolls in skin pass mills

• Vacuum squeezing roll systems as an energy saving replace-ment strip dryer

• High temperature brush transport rolls for hot and cold strip on continuous furnace lines

• Brush transportation rolls for reducing noise on slitting and cross-cutting lines for heavy plates

• LOAD RUNNERS® heavy load rolls in coil transportation devices or roll exchange vehicles.

Steel mill Hot rolling mill Pickling line

Anealing and pickling line

Anealing and pickling line

Bright anealing line

Cold rolling mill

Stretch levelling line Stretch levelling line

Slitting line Cross cutting line

Slab Wide strip Wide strip Slit coil Blanks Wide strip Slit coil Blanks

Hot strip Cold strip

Process chain of stainless steel flat products manufacturing

Where stainless steel materials reach their limits in high acidconcentrations, special protective coatings on shafts andaccessories secure the optimal protection of these compo-nents. In addition, for cost reasons steel shafts with shock andimpact resistant coatings have come to represent an interest-ing alternative to stainless steel bodies.



Roll coating control

Almost 50 years ago, OSBORN developed a revolutionarytechnology using brushes in the continuous rolling processin order to optimally regulate the oxide film on working andback-up rollers in hot rolling mills. Meanwhile, hundreds ofrolling hot mills worldwide have been equipped withOSBORN technology. To date, specially designed wire qual-

ities, abrasive multi-filaments, individually camber groundsurfaces and extensive experience in optimising the use ofbrushes in numerous individual applications have secureda big technological advantage for us in this field, fromwhich our customers benefit worldwide.

2.6


Roll coating controlAluminium

Non ferrous

HRM, HRFM, HFM

HCM

Control of the oxide layerand removal of oxides

Helimaster® Brush rolls abrasive or wire-filled

Lateral rings made of composite fibre materials for limitingimmersion depth and sleeves for splash guarding journalsand bearings - developments created by OSBORN.

On hard chrome working rollers, abrasive multi-filamentswith a high density achieve a particularly uniform brushingand cleaning of the roll surfaces.

13


14

Precision camber ground - for optimum brushing results

The individually adapted camber ground of the brush rollerbody is one of the most important prerequisites for ensur-ing uniform brushing across the entire width of the roll.Convex or concave contours are ground, depending on theconstruction of the working or back-up rollers to be

brushed, and the calculation of the optimum crown is car-ried out. OSBORN of course also grinds brush rollers witha CVC contour on CVC technology mills for roller gapadjustment.



Transport roll systems for HHT furnaces

The tempering of hot mill plates made of precipitation hard-ening aluminium alloys through the process of solutionannealing serves the purpose of attaining higher strength andstrain values along with a good level of corrosion resistancefor the material. Today, this is required for structural parts inaircraft in accordance with the high requirements of stan-dards AMS 2750D, AMS 2750C and AMS-H-6088. The careful transportation of these aluminium plates in ‘hardmetal and hard material technology’ roll hearth furnacestakes place as a batch or reversing process at temperatures

of up to 600°C on brushed transportation rolls. In close coop-eration with leading equipment manufacturers, numerousfurnaces around the world have been equipped in recentyears with OSBORN’s sophisticated technology. In theprocess, plates with thicknesses of up to 400mm, lengths of20 metres and weights of over 10 tonnes do not represent aproblem for us. Tolerances have been continually reducedand product features optimised, so that now more than ever,the brush roller is an important and technically superior com-ponent in the overall design of the line.

2.7

15


Transport roll systems for

HHT furnaces

Brush transport rolls; HHTbrush transport roll systems;

Furnace capacity increaseconcepts

Aluminium

Transportation of hot platesthrou the heat treatment pro-cess; optimized heat transfer;

Avoidance of transport roll pick-up and surface damages

HHT plate furnaces

Surface-sparing plate tracking with longstanding roll lifetimes

With brushed furnace transportation rolls, OSBORN cus-tomers can today place their trust in several decades of expe-rience and well known global references. In the complex pro-duction of the rolls, some with a total length of over 6000mmand 4000mm of brushed length, the highest levels of preci-sion and reliability are required in all manufacturing process-es. After the rolls have been manufactured, the later course ofthe sheet is accurately simulated in advance in our factory.

For roll assemblies in new furnace lines, this allows OSBORNto guarantee an optimum course of the sheet within tight tol-erances even when starting up the run.

In order to guarantee the lowest possible of amount of sheettracking, with the ‘re-brushing’ of entire furnace zones, thetransportation of the sheets is simulated on an in-house testrig just like new lines.


16

This advanced technology provides convincing arguments asto why brushing using heat resistant wires is increasinglyestablishing itself as a roller cover for furnace transportationrolls.

• Optimum heat transfer between the transportation roll and the plate

• Lifetimes of several decades without significant wear of the brushes

• Complete avoidance of scale pick-up and spot formation on the surface of the roller, just as is mostly the case with self-contained roller coverings

• Total-care transportation of the plates during the heat treat-ment without damaging the surfaces of the plates

Apart from the production of new rolls, the recovering andreplacement of worn brushes in older lines is also one of ourcore competences.

By precisely measuring the course of the plate as well as thestate of the individual rolls within the furnace by means ofself-developed test equipment, we are able to optimise platetracking if needed and through this, to optimise the output ofthe entire system.

Plate tracking after optimization as per OSBORN recommendation

Capacity optimization at older furnace installations

Plate tracking in initial state

Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6

Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6


Carbon steel

Stainless steel

Aluminium

non ferrous


Transport roll systems for high temp applications

Roll coverings made from extremely dense stainless steelwires in special alloys which are resistant to high tempera-tures provide specific product features and strong advan-tages compared to uncoated transportation shafts or furnace

rollers with ceramic coatings. These can be used in differenthorizontal heat treatment lines for strips of steel, stainlesssteel or nonferrous metals.

2.8

17

Excellent brush lifetimes without scale pick-up - up to 1100°C

Properties and Advatages

• Temperature resistance of up to approx. 1100°C

• Shaft construction with internal cooling

• Extremely dense and accurate neutrally ground surface of the rolls

• Significantly better heat transfer characteristics of the tips of the wires when compared to surfaces made up wholly of material

• No scale pick up (formation of spots) on account of the absorption properties of the exposed brush surface

• As a result: Reduced maintenance


Transport roll systems

for high temp

applications

CAL, CGL

BAL, CAPL, CAL, HAPL

HHT Bandofenanlagen

High temp brush transportrolls; Brush transport roll

systems

Transportation of high temp strip;Avoidance of transport roll pick-up

and surface damages

• As a result: Particularly careful transportation of the plates and reduction of damage to the surface

• Very low wear to the rolls with significantly longer lifespan than ceramic coatings or other roll coatings (in comparison)


18


Transport roll systems

for noise reduction

Carbon steel

Stainless steel

Aluminium

Non ferrous

SL, CCL transportroll tables

Low noise surface friendlytransportation of plates or

sheets

Noise-reduction transportrolls; Noise-reduction transport roll systems


Transport roll systems for noise reduction 2.9

When transporting the sheets onto rolling tables, extremenoise levels may occur in slitting/cross cutting lines for heavyplates after the shearing process. At over 110 dB, this maypossibly exceed the threshold of noise pain for the humanear.

By coating the bright transport rollers with brush sections,the noise level can be reduced to around 70 dB so that a riskto health in terms of occupational health and safety is signif-icantly reduced.

All in all, our brushed transportation rolls offer a number ofadvantages for the user through their positive product fea-tures:• Significant noise reduction in transporting sheets > 30%• As a result: improved and safer working conditions• An overview is achieved with regard to purchasing costs

through the equipping of existing shafts with brush cartridges in sections

• Less wear of the heavy wire brush roll surface• As a result: roll service lives of up to 10 years • Particularly careful transportation of the sheet surface• No soiling of the roll surface through the absorption of dirt

into the brush lining• As a result: Reduction of maintenance costs for the rolling

table

120 dB 110 dB 100 dB 90 dB 80 dB 70 dB 60 dB

Pain threshold Obligation of ear protection

Noise level reduction

from 110 dB to 70 dB

with OSBORN transport rolls


Brush roll systems

Complete brush roll systems

Through many years of cooperative development work withmachinery manufacturers in the design of rolls and brushingmachines as well as with the operators concerning produc-tion line and process optimization, OSBORN has an estab-lished wealth of experience in this field. Through our world-wide sales and service network we are able to guaranteecomprehensive technical support for new production lines

around the globe in all stages of project development, fromthe initial design to commissioning. A whole host of well-known manufacturers in the business of strip and heat treat-ment plants and rolling mill technology benefit from thisexpertise which ultimately rewards the plant operator in theform of well-engineered products and innovative technolo-gies.

3.1

19

Product group OSBORN product range


Shafts for brush rolls

Brush roll fillings

Re-usable tube bodies

Shafts for back-up rolls and other roll types

Balancing collars

Bearings and Complete bearing units

Splash rings

Other fittings and accessories

Transport boxes and packaging concepts

Customized solutions for equipment manufacturers

Apart from the manufacturing of complete brush rollers withdifferent shafts and body constructions, our range of servicesalso includes the bearing units, splash rings and accessories.

In addition, we also manufacture and supply shafts and com-plete systems for other roll types used in strip line systems.These come without or, on request, with hard chrome,polyurethane, rubber or other special coatings.


20

The construction of bodies with hollow shafts suitable forinternal cooling is primarily used in abrasive brushes forheavy-duty applications. Apart from improved brush coolingwith greater frictional heat when used in corrosive media,they continuously and uniformly rinse the brush in operationfrom the inside out by means of the centrifugal force, whichleads to an improvement in the brush’s lifetime.

Lateral balancing rings with trapezium grooves and slidingbalancing weights serve to dynamically balance the shaftsfrom grades G 1 to G 6.3 in accordance with DIN EN ISO1940. With certain material grades it is a good idea to pitchthe balancing nut in order to ensure simple disassembly.


Brush roll systems

Factory Assembly (FA) brush roll systems

At OSBORN, decades of global expertise is consistently com-bined with a local, comprehensive all-round service packageon the customer’s premises. In addition to six centralisedtechnology centres in Asia, Europe and North and SouthAmerica, the other service centres belonging to the various

OSBORN factories or local partners spread over many coun-tries offer a comprehensive service for your rollers. Thisallows customers around the globe to directly benefit fromour technology and the comprehensive range of services on-site.

3.2

21


Factory Assembly (FA)

brush roll systems

Integrated maintenance service

Brush roll re-filling (SPW/NB)

Integrated maintenance service concepts

Re-trimming and re-balancing of brush rolls

Shafts and journal control and repairing

Bearing control and exchange

Shaft improvement/adaptation

Shaft straightening

Stress free annealing of shafts

Replacement of end and balancing collars

Replacement of fittings and accessories

Transport and packaging concepts

Supply of brush roll trimming equipment

We combine global know-how with local full service

An extensive transportation network, partly with company-owned vehicles, provides a quick and easy collection andreturn service for customer rollers.

Apart from the direct re-brushing of customers’ shafts or theon-site assembly of brush cassettes, our comprehensiverange of services includes all worthwhile and necessaryinspections as well as repair and service work relating to ourcustomer’s rollers.


22

Upon receipt by our service centre, each roller immediatelyundergoes a professional inspection in accordance with theextent of the agreed service contract. The condition as well asthe time and expense involved with the maintenance are doc-umented with the aid of standardised protocols.

The quiet and low-vibration running of the rollers is impor-tant in order to avoid shatter marks or shading on the stripsurface caused by the brush roller. Before recovering, eachshaft is therefore examined with regard to inbalance and con-centricity deviation, in order to align it straight away if neces-sary and to rebalance it.

The longer the service life of rollers, the more important is aproper condition of the bearings for avoiding additionaldowntime or outages. For this reason, bearing units arechecked and maintained by us. If necessary, the bearing unitor other accessories are renewed.

Worn bearing seats are welded and precisely re-machined tothe original specification.

Following this, immediate re-brushing or the assembly ofpreviously prefabricated brush cassettes takes place.

Conditioning

Reworking


Brush roll systems

Customer Assembly (CA) brush roll systems

OSBORN has the right solution for customers who want torecover and maintain their brushes in-house – roller systemsfor self-assembly. Our range of products and servicesincludes cassettes in fully-automatic internally-welded spiralconstructions, disk constructions as well as constructionsassembled on one-way tube bodies and older structures withsingle discs or loose spirals. In order to individually adaptthese to existing shaft constructions, they are additionallyprovided with one-way adapters, if required. As such, we can supply the right cartridge for almost every

different shaft that a customer has, like no other manufactur-er in the world.

At the same time all of the usual filaments, wires or naturalbristles can be processed and realised according to individualrequirements at different trim lengths and densities - fromlight to standard, to extremely dense.

We also provide the right equipment for simple follow-upshearing of the roller on a lathe.

3.3

23


Customer Assembly (CA)

brush roll systems

Cassete brush rolls - spiral type (SPW/IV)

Cassette brush rolls - disk type

Brush rolls - one-way tube construction (SPW/RK)

Hotani® Cassete brush rolls

Single brush disks

Loose spiral coils (SPW/LS)

Cassette systems for simple self-assembly onto customers’ shaft

Intelligent and well-engineered roll constructions withoutcomplicated clamping systems make the simple and fast,immediate exchanging of brush coverings on the spot abreeze.

OSBORN brush cassettes are trimmed in sets. Each individualsegment is labelled and marked in accordance with theassembly instructions. This ensures simple and completeassembly without diameter variations.


24

With modern shaft constructions from OSBORN it is possibleto dispense with balancing the shafts.

Precision manufactured inner diameters, in narrow toleranceranges ensure that the individual cassettes optimally sit onthe on the shaft and prevent vibrations when running.


Brush roll systems

OSBORN HDL® brush rolls

OSBORN International once again sets a new benchmark inbrush technology with HDL® brush rollers - the latest devel-opment from us. By combining streamlined brush construc-tion with specially developed micro fibre fill materials, it hasbeen possible to realise and successfully introduce a productwith significantly improved performance levels and wear

properties. In addition, the expertise from years of closecooperation with technology partners and line manufacturersin Japan, Europe and the United States as well as from theever increasing demands on line operators has been broughttogether.

3.4

25


OSBORN HDL® brush rolls

OSBORN HDL® - the benchmark in lifetime and brush performance

OSBORN HDL® conceals even more than this. What we meanby this is an optimisation approach to strip lines with regardto the various brush applications as well as the usage param-eters of these rollers.

Initially, the current weaknesses will be analysed. Dependingon the type of line and degree to which the brushes arerequired for cleaning, degreasing and surface activation, an

individual covering is defined for the roller which is madefrom non-abrasive and/or abrasive micro fibres and monofil-aments. In parallel, the shaft construction is optimised andadjusted. In general, the customers’ existing shafts can beused. In addition, the usage parameters of the respectivebrush rollers are evaluated with regard to cooling, in-feed andrevolution speed and an individual optimisation recommen-dation is drawn up.

Microfibre/multifilament high-density brush rolls, abrasive or non-abrasive

Individual concepts improved brushing application in process lines (lifetime and brush performance)


Factory Assembly (FA) brush roll systems

Customer Assembly (CA) brush roll systems

Adaption/improvement of existing rolls/Shafts


26

Compared to conventional standard brushes, OSBORN HDL®

rollers offer decisive advantages:

• Significantly increased lifetimes and reduced operating, maintenance and overall brush costs

• Improved cleanliness levels in strip cleaning make a contri-bution to quality improvements, process optimisation and increases in line speed

• The targeted and better control of the rollers due to the compact design with higher density makes a significant contribution to reliability and controlled process control

Unlike conventional mono-filaments with bristle diametersranging between 0.15 and 1.5 mm our Novofil micro-fibrematerial can also reach, in a targeted way, the rough depthsof strip surfaces to be brushed due to their very thin threadthicknesses of up to 0.02 mm, which brings with it signifi-cantly improved cleaning and degreasing levels. In theprocess, a multi-filament bristle can be made from severalhundred micro fibres.

Micro filaments improve strip cleanliness

Due to the extremely high density and the individual mix withnew, especially hard and rigid abrasive materials, heavy soil-ing and coarse metallic rolling retentions are removed in away which is better than ever before.


Brush roll systems

Lipprite® abrasive non-woven rolls

Through the merger of the corporate groups OSBORNInternational and Lippert-Unipol, we have been able to signif-icantly expand our range in the field of rollers for achieving atechnical or optical surface finishing.

In the process, Lipprite® abrasive rollers represent an alterna-tive to brush rollers in various applications. Besides finishingapplications, they are used for working roll cleaning, for sur-face activation, as well as for de-scaling.

3.5

27

Lipprite® - the abrasive alternative for a perfect surface

The processing results achieved by Lipprite® abrasive rollersmay vary a lot depending on the roller specifications, surfaceand individual usage parameters. For orientation, the follow-ing approximate values for the achievable surface roughness(Rt) are:• A4 (coarse) = 3.3 - 3.9 mm• A6 (fine) = 2.9 - 3.6 mm• A7 (very fine) = 1.1 - 1.8 mm

Overview of the roller coverings and material specifications for Lipprite® abrasive rollers

Based on many years of experience or by individual tests onour test lines, we are able to specify the right product in a tar-geted way for almost any surface roughness required.Contact our application engineers.

Aluminium oxide abrasive grain (AI2 O3)

A1 extra coarse XCRS Grain 36A2 coarse CRS Grain 80A4 medium MED Grain 100A6 fine FN Grain 180 (240)A7 very fine VFN Grain 280 (320)

Different hardness specifications for Lipprite®

103 - soft105 - medium107 - hard109 - very hard

Silicon carbide abrasive (SiC)

S4 medium MED Grain 100S6 fine FN Grain 180 (240)S7 very fine VFN Grain 280 (320)S8 super fine SFN Grain 500S9 ultra fine UFN Grain 800S10 micro fine MFN Grain 1500

Additional Lipprite® impregnation for increase lifetime and

roller corrosiveness

PH 90 Standard hard impregnationPH 120 extra hard


28

Technical data and product characteristics:

• max. roller width 2000mm• max. roller diameter 450mm • Version available with or without impregnation • Rollers are dynamically balanced in accordance with DIN

EN ISO 1940

Recommendations concerning the use of rollers:

• Use in wet or dry operations• Optimum cutting speed 15-25m/s • Line (strip) speed or feed speed up to 30m/min. (max.)• Processing in the opposite direction to the running direction

of the material feed• Optimum depth of immersion 2-6mm, depending on the

roller diameter and hardness • Oscillation improves the uniformity of the machining profile

Lipprite® abrasive rollers are manu-factured from abrasive non-wovenflaps through radial adhesion to acore. The abrasive grinding grainmade of silicon carbide (SiC) or alu-minium oxide (Al2O3) is at the sametime, embedded into the surface ofthe random web fibre non-wovenmaterial (made of polyamide or other synthetic material) bymeans of resin. The corrosiveness of the roller is individuallydetermined by the density of the pressure, i.e. the number offlaps.

An optional additional impregnation makes the roller evenmore corrosive and increases the lifetime. It is necessary tobear in mind, however, that because of the significantlyincreased hardness, impregnated rollers are less flexible. Assuch, surface undulations can be harder to balance, whichmay result in a less uniform finish or in terms of the machin-ing profile, visual shading.


NOVOTEX® non-woven rollsProducts and applications

Strip lines and rolling mills are equipped with a large numberof different rolls for completely different tasks and applica-tions. Through ever-higher line speeds and steadily increasingdemands in terms of quality and process reliability, thedemands made on roll covers and surfaces also increases. Assuch, non-woven rollers, with their special material proper-ties, become increasingly important within the steel, alumini-um and non-ferrous metal industry.

In parallel, through close cooperation with one of the world’sleading manufacturers of technical non-woven materials,OSBORN has managed to develop a well-engineered seriesof products under the NOVOTEX® brand name, which are ableto fully satisfy the consumer’s expectations in terms of quali-ty, reliability, durability and an excellent price/performanceratio.

4

29

NOVOTEX® - convincing in quality and profitability

Material properties and technical benefits

OSBORN’s NOVOTEX® rollers are used where other syntheticroller coatings reach their limits and can no longer ensureoptimum results or stable processes, as compared to rubberor polyurethane, non-woven material offers crucial advan-tages.

• The porous structure of non-woven fabric in combination with a large pore volume makes the material compressible

• The capillary or suction effect when discharging the non-woven structure provides a significantly lower amount of residual moisture in squeezing applications

• In contrast to elastic, but hardly compressible rubber or polyurethane coatings, a significant adhesion effect occurs in the contact area for the strip surface which is under pres-sure. Taking these roll coverings into consideration, this is something that leads to significantly higher and more con-

stant coefficients of friction.

• It is significantly easier to avoid aquaplaning effects

• Through the applied pressure of the random web with high pressure on a roller core, a roll coating arises which, with a hardness of up to 95 shore A, exhibits an enormous resist-

ance to being cut as well as a ‘self-healing’ effect in theevent of light cuts

1 mm 1 µm


30

• This results in excellent wear characteristics with a much higher roll lifespan in comparison to rubber or polyure-thane

• Due to its pore volume, the roller covering is in the posi-tion to absorb small particles of dirt, oil or grease residue as well as light roller tinsel

• For a sustained period, the surface itself remains largely free of contamination or hardened material - an important criterion for permanent, reliable roll operation without fluc-tuations in quality

• In addition, the strip surfaces are particularly conserved and protected from damage

Economic benefits

The material properties and technical benefits describedbring about a series of economic benefits, which makes theuse of non-woven fabric rolls an interesting proposition froma cost/benefit point of view:

• Despite significantly higher acquisition costs for the individual rolls, the much longer service life ensures a reduction in operating costs on balance

• Significantly longer lifetspans for the rolls reduce downtime and as such, reduce maintenance costs

• Even with the aid of the non-woven roll, quality and process improvements gained in manufacturing operations con-tribute to an increase in economic efficiency

NOVOTEX® non-woven roll

Friction coefficient as a feature of the oil film for solvent based liquids

0,30

0,25

0,20

0,15

0,10

0,05

0,00

0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00 4,50 5,00 5,50 6,00 6,50

Area weight of oil film (g/m2)

Fri

cti

on

co

eff

icie

nt

Material compressibility of non woven

Compression Expansion

Conventional rubber roll


31

Product group OSBORN Product range

NOVOTEX®

non-woven rolls

Non-woven coverings and re-coverings

Shafts for non-woven rolls

Complete rolls incl. shafts and bearing units

Integrated maintenance service concepts

Re-trimming and re-balancing of used rolls

Partial repair of damaged roll coverings

Shaft and journal control and repairing


Replacement of fittings and accessories

Transport boxes and packaging concepts

Product range

Apart from non-woven fabric coverings our range of productsincludes the production of shafts as well as the recovering ofworn out rolls. We offer complete package systems specifical-ly for the construction of lines including bearing units and

shaft accessories. Users can benefit from our maintenanceservice which includes the examination and repair of dam-aged rolls as well as accessory parts.


32

OSBORN NOVOTEX® non-woven material range

Technical data

Basic fibre

Range of hardness

max. operating temperatures

max. line loading at <~200 m/min. line speed

max. line loading at >~200 m/min. line speed

max. line loading at >~300 m/min. line speed

PA PA PA PP

90-94 shore A 70-85 shore A 90-95 shore A 70-80 shore A

100°C 100°C 130°C 80°C

50 N/mm 20 N/mm 100 N/mm 15 N/mm

30 N/mm 10 N/mm 80 N/mm 10 N/mm

20 N/mm --- 50 N/mm ---

Application data

oil and emulsions oil and emulsions oil and emulsions acids, alkalineswater water solvents oil and emulsions

squezzing, pinching squezzing squezzing, driving squezzingbreaking

Applicable for liquid categories

main applications

Material type

Colour

NOVOTEX® 09 NOVOTEX® 10 NOVOTEX® 11 NOVOTEX® 12

Brown Pink Orange Grey

Materials

When selecting the optimum non-woven fabric for the indi-vidual application we can rely on the various material quali-ties which have been tried and tested and continuouslyimproved over the years and which can be easily distin-guished by different colours.

Through the new development of the NOVOTEX® 12 coveringmaterial based on polypropylene, we have now also coveredsqueezing applications in acidic cleaning and/or pickling sta-tions using non-woven material.

ForceBending X/Y - level

Too low force: wet edges

Too high force:wet centre

To specification:uniform break

Camber ground

The roll deflection is of crucial importance for an optimumand uniform squeezing result over the entire width of thestrip. This is especially the case in weak or undersized shaftconstructions. When the feed is too high the roll ‘whips’ lead-ing to excessive residual moisture in the central area, whiletoo little feed force causes wet edges or border areas.

For this reason, OSBORN International defines the optimalfeed force for each non-woven roll and on this basis, worksout the expected roller deflection. The roll balling will beground to exhibit convex or concave contours.


33

Applications

Non-woven rolls can be used in all strip lines or rolling millsfor steel, stainless steel, aluminium and non-ferrous metals,e.g.

• Hot-dip galvanizing lines• Continuous annealing lines• Annealing and pickling lines• Cold rolling mills• Skin-pass mills• Colour and/or organic coating systems• Electrolytic galvanizing lines• Cleaning or degreasing lines

and a whole range of other types of line. They also signifi-cantly contribute to improving product and process quality.

OSBORN Innovations for cleaning sections in strip processing lines

Alkaline brush

cleaning

Squeezing rolls Brush

cleaning

Squeezing

rolls

Squeezing

rolls

Alkaline spry

cleaning

electrolytic

cleanining

Water rinsing Hot Air dryer

OSBORN HDL® NOVOTEX® NOVOTEX®OSBORN HDL® NOVOTEX®

Load Runners® Brush sealings

Besides NOVOTEX® non-woven rollers, the OSBORN rangeincludes more innovative products for cleaning sections instrip lines, such as HDL® brush rollers, Load Runners® andinnovative equipment technology.

Brush sealing units which come in temperature, alkaline oracid-resistant versions for sealing strip inlets and strip outletson line components, complete our range.


34

Applications

Pressure rolls

S-rolls / Tension rolls / Bridle rolls

Squeezing rolls

Deflector rolls

Transport rolls / Carrying rolls

Tension rolls /Brake rolls

Applicator rolls

When used as bridle rolls, tension rolls, steering rolls or

deflector rolls the advantages of non-woven fabrics overother synthetic coatings are especially clear. In a dry state andespecially in a wet state, a non-woven fabric has an excellentand, above all, constant friction coefficient, both on oil as wellas on watery media. The friction coefficients of rubber orpolyurethane-coated rollers however, are very low; some-thing which can easily lead to aquaplaning in the case of non-driven roller, i.e. a floating of the roller, resulting in strip slip-page and through this, scratches and damage to the surface.On the other hand, non-woven coatings adhere well to thestrip surfaces. This allows much higher tensile forces to beachieved and strips can be held tightly and controlled muchmore accurately.

Even when applied to braking or tension rolls, these materialproperties speak in favour of the non-woven roll. Because ofthe strong and stable adhesion between the roll and the stripsurface, strips can be evenly pulled or control-braked, even athigh plant speeds.

Squeezing rolls ensure lower residual moisture than rubberor polyurethane coatings. On account of the capillary or suc-tion effect of the non-woven material, fluid displacement atthe edges is reduced and the strip edges dry better. In addi-tion, the special properties of non-woven materials provetheir worth in terms of resistance to cuts and durability.

As oiling or applicator rollers, non-woven coatings ensure theuniform application and distribution of liquid coatingsbecause of their sponge effect. Due to their porosity and porevolume, they are in the position to absorb liquid and underpressure, to dispense it again evenly and/or to distribute it onthe surface.

The special surface protection which is created by absorbingsmall dirt particles into the roller surface is apparent in pres-

sure rollers made of non-woven material, especially for softand sensitive surfaces, such as aluminium e.g. coil strips incold rolling processes. Line speeds of over 1000m / min rep-resent no problem.

A similar situation applies to the use of non-woven roller as atransporting or carrying roll. The soft and absorbent surfaceof the roll prevents scratches or damage, thus ensuring thesmooth transfer of the strip.



Vacuum squeezing systems

By connecting of a pair of squeezing rolls made from specialmicro fibre non-woven material with simple vacuum technol-ogy, we are able to offer an innovative, energy-saving andwith it, a particularly environmentally-friendly system forstrip drying in a variety of process lines. Through this tech-

nology, which has been proven and established in Japan fordecades, it is sometimes possible to dispense entirely with afan or hot-air dryer. As a result, a single line can achieve annu-al energy savings of up to EUR 100.000.

5.1

35

Dry surfaces and very low energy consumption - without hot air

Product group OSBORN Product range

Vacuum squeezing rolls

Complete systems including vacuum pump

Microfibre squeezing rolls

Complete units including frame construction

Service and repair of used rolls

Supply of equipment for retrimming of used rolls


The function of the system is simple. The role vacuum gener-ated on the perimeter sucks the liquid remaining on the stripsurface into the roll, supported by the capillary action of themicro fibre non-woven covering. Through the hollow shaft onits perimeter, which has numerous holes on it, send is then fedagain, via the vacuum pump, to the existing fluid circuit.

Significant quality or process-related optimisation has also beencreated through the vacuum technology, with absolute dry stripedges being just one leading example. Media displacementthrough the gap in the squeezing rollers in the edge area is elim-inated entirely by the strong vacuum function and the need forsubsequent expensive/laborious drying is dispensed with.


36

The advantages of the vacuum roller especially come intotheir own in comparison to conventional squeezing rollers onshatter plates or extremely rough strip surfaces.

The rolls function with a very soft surface and only minimalcontact pressure. As such, the coating is significantly less

prone to wear and essentially more resistant to damage fromstrip edges than is the case with traditional squeezing rolls. Without its own power, the limited in-feed of the roll pre-serves the condition of the rolls, as well as the bearing andthe line itself. This creates a lifespan for the rolls averagingfour to five years (depending on individual application) withonly minimal maintenance. All that is needed is one trimmingsession and follow-up grinding of the roll surface from timeto time.

Another important advantage is that this system innovation isextremely simple to implement into existing strip lines. Onlythe last pair of squeezing rolls in the plant has to be swappedover. At the same time, the external dimensions of the rollsnormally remain unchanged and the existing bearings can beused. Even when additionally installed into an existing stripline, the space requirement for a complete unit with a frameconstruction is less than one metre in width. The vacuum unititself also requires very little space and does not have to beplaced directly on the pair of rolls.

In the example below, of a typical strip cleaning line throughthe use of NOVOTEX® non-woven rolls in the third and fourthexchange of the squeezing roller pair, it would possible to dis-pense with the hot-air drying facility entirely in favour of avacuum squeezing system.

Tell us your specific problem in detail and we will prepare a

proposal for a coherent optimisation concept.

Vacuum squeezing system

can replace hot air drying

Squeezing rolls

Water rinsing section

NOVOTEX®

Microfibre squeezing rolls in combination

with energy saving vacuum technology


Along with this background, we are also able to offer a new, fullypatented machine package which includes a variety of innovativedevelopments:

• A rigid machine housing which is heavily cushioned against vibrations and protected against corrosion, made of a composite stainless steel/mineral cast construction

• Compact and extremely dense OSBORN HDL® brush rollers enable precise control of the depth of immersion

• Easier and quicker replacement of the rollers within a few minutes using an insertion skid with no additional dismantling tools

• Compact design enabling the unit to require little space - only 1500 mm for each upper/lower brush for strip widths up of to approx. 2000 mm


Brushing equipment for strip processing lines

By linking our technological leadership in brush rollers withthe competence and experience gained from teaming up witha whole range of line installers across the world we are, incooperation with selected partners in the field of mechanicalengineering, in the position to offer well-engineered and indi-vidually adapted brushing machines and line concepts whichgo further than the established standards of simple new

plant. Our focus primarily lies in swapping old machineswhich no longer work optimally in existing lines, while at thesame time optimising brush rollers and usage parameters inorder to achieve sustainable quality and process improve-ments.

5.2

37

Brush / Brush

Low vibration

New intelligent concepts for brushing machines

Brush / Back-up-roll

Increased vibration

• Easy and precise positioning of the rollers through mechanical clamping

• As a result: optimum and consistent, reliable feeding of the brush rollers via the immersion depth by means of height adjustment using precision lifting spindle elements with a servo positioning motor (parallelism tolerance approx. 0.1 mm)

• Replacement of the rollers without disassembling the bearing units

• Optical control at any time through side access doors with large win-dows on the operator side and the interior lighting of the plant

• Non-contact measurement of the roller diameter in operation

• Optional construction according to the brush/brush principle


38

For many years, lines according to the Japanese design haveenjoyed a technologically leading role. In recent years, wehave able to successfully realise new line projects withrenowned steel producers in Europe, North America, Asia andAfrica together with our Japanese partners, by adjusting thecomponents to international standards.

• With these lines, the brush/brush principle instead of the conventional brush/back-up roll design brings a number of advantages with it.

• Due to the halving the amount of roll pairs which are

required, a 50% space saving is achieved.

• In the case of thin straps, the brush in the border area no longer works on the back-up roll but combs in the opposite brush. Fully uniform wear of the brush balling is achieved in the border area through the additional oscillation of the rolls.

• In all, the performance of the respective strip cleaning unit

is significantly improved, and in turn this can contribute to improving the strip quality and an increase in the line speed.

• Acquisition and maintenance costs are correspondinglyreduced.

• Above all, when exchanging brush machines in existing strip lines, valuable space for additional pre-cleaning sections

can be achieved alongside more intensive brushes.

• The contact surfaces strip/upper brush and strip/lower brush are identical. This reduces vibrations. Through gentler run-ning of the strip brush shading and shatter marks on the strip surface are avoided.

Brushing machine in brush / brush construction including oscillation


Load Runners®

Idler rollers and load rails

The name Load Runners® stands for five decades of experiencein manufacturing of idler rolls and guidance systems for preci-sion moving heavy loads in difficult conditions. Line buildersand operators of rolling mills, strip lines or heat treatmentplants trust in OSBORN’s coil, plate, tray and roller transport orbearing equipment as well as the company’s automatic doorsand a whole host of applications based on this technology.

Apart from an extensive standard program of over 300 arti-cles in stock or available at short notice up to a diameter of250mm, special sized rolls can also be tailor-made in smallquantities for special requirements.

6

39

Load Runners® carry heavy loads in harsh environments


Load Runners® idler rolls are tightly sealed and greased fortheir entire service live. As such they are insensitive to dirt,moisture and extreme temperatures. Long-life maintenance-free operation ensures high levels of economy without main-tenance.

The treads are made of high-strength steel and are then sur-face hardened to 55-60 HRC. As such they feature an espe-cially wear-resistant surface with a tough core.

The precision tapered roll bearings and grooved ball bearings

used are particularly suitable for both radial and axial loadsand can even be used at high speeds. This ensures key advan-tages over conventional needle bearings.

Precision adjusted and hardened guiding rails made of high-duty alloy steel are extremely resilient, wear resistant andfree from twist effects. As such, heavy loads can be movedprecisely and reliably.

Types

40

Plain Stud Style

· radial and thrust loads· easy to install

Plain Eccentric Stud Style

· radial and thrust loads· easy to install· vertical adjustment

Plain Yoke Style

· radial and thrust loads· higher capacity than stud style

Flanged Stud Style

· radial and thrust loads· easy to install

Flanged Eccentric Stud Style

· radial and thrust loads· easy to install· vertical adjustment

Flanged Yoke Style


V-Grooved Stud Style

· radial and thrust loads· roller profile sheds solid contaminants

V-Grooved Eccentric Stud Style

· radial and thrust loads· roller profile sheds solid contaminants· vertical adjustment

V-Grooved Yoke Style

· radial and thrust loads· higher capacity than stud style· roller profile sheds solid contaminants

Cam Runner

· composite outer· stainless steel shaft· wet environments

U-Grooved Stud Style

· wire guides· idler pulleys· easy to install

Flanged Crown Style

· concentric and eccentric· radial and thrust loads· use on channels and I-beams

Crown Yoke Style


Shafts for Yoke Style Idler-Rollers

Our complete Load Runners range

can be found in our catalogue,

“Load Runners® - Idler-Rollers and

Load Rails for high-capacity load

handling”.


Fill materials7

41

Synthetic monofilaments - NON ABRASIVE

No

vo

fil

NN

No

vo

fil

NM

No

vo

fil

NH

No

vo

fil

HR

No

vo

fil T

R

No

vo

fil

PR

No

vo

fil

PT

Material group PA 6 PA 6.6 PA 6.12 PA Special PP PBT

Density (g/cm3) 1,14 1,1 1,07 1,14 1,16 0,9 1,5

Temperature resistance

Permanent (°C) 90 90 90 95 190 70 100Max. short-term (°C) 120 120 120 120 250 100 130

Water absorption

(at 23°C) 10% 8% 3% 9% 7,50% <1% <0,5%

Mechanical properties

Bend recovery + + + + + 0 -Stiffness - 0 + - 0 + +Resistance to abrsion + + + + 0 0 -

Chemical resistance

Against alkalines + + + + + 0 0Against acids - - 0 - + + +

Synthetic monofilaments - ABRASIVE

No

vo

fil

NH

-S

No

vo

fil

NH

-A

No

vo

fil

NN

-S

No

vo

fil

NN

-A

No

vo

fil

HR

-S

No

vo

fil

HR

-A

No

vo

fil

NL-

S

No

vo

fil

NL-

A

No

vo

fil

NH

-C

No

vo

fil

NA

-S

No

vo

fil

NA

-AMaterial PA 6.12 PA 6.12 PA 6 PA 6 PA 6.12 PA 6.12 PA 6.12 PA 6.12 PA 6.12 PA 6.12 PA 6.12

Abrasive Material SiC Al2O3 SiC Al2O3 SiC Al2O3 SiC Al2O3 Al2O3 SiC Al2O3

Grit size 46-1000 80-1000 46-500 60-500 46-500 80-500 46-320 120-320 80-320 46-500 46-500

Density (g/cm3) 1,3 1,5 1,3 1,5 1,3 1,5 1,3 1,5 1,65


Permanent (°C) 90 90 90 90 95 95 90 90 90 80 80Max. short-term (°C) 120 120 120 120 130 130 120 120 120 110 110

Water absorption

(at 23°C) 3% 3% 10% 10% 3% 3% 3% 3% 3% 1,50% 1,50%

Mechanical properties

Bend recovery + + 0 0 + + + + + 0 0Stiffness + + 0 0 + + + + + 0 0Resistance to abrasion + + 0 0 + + + + + + +

Chemical resistance

Against alkalines + + + + + + + + + 0 0Against acids 0 0 - - - - - - - + +


42

Ste

elw

ire

CD

Ste

elw

ire

AB

Ste

elw

ire

Bra

ss c

oate

dS

teelw

ire

Co

rdw

ire

Sta

inle

ss

Ste

elw

ire

ho

ch

ko

rro

sio

ns-

bestä

nd

iger

Ed

els

tah

ldra

ht

ho

ch

tem

pera

tur-

bestä

nd

iger

Ed

els

tah

ldra

ht

Bra

ssw

ire

Bessem

er W

ire

Ph

osp

ho

r-B

ron

ze

Dra

ht

Material group Carbon Steel Steel Steel Steel 1.4301 1.4401 Special Brass Steel Phosphorsteel legiert hochlegiert brass coated brass coated 1.4541 1.4571 soft Bronze

Type crimped crimped crimped crimpedcrimped crimped crimpedcrimped crimped crimpedcrimped

Density (g/cm3) 7,85 7,85 7,85 7,85 7,85 7,90 8,00 8,00 8,30 7,80 8,90


Permanent (°C) 300 300 300 300 300 620 500 1150 170 250 170

Wear properties

Elasticity modul (kN/mm2) 210 210 210 210 210 195 195 195 80 200 110Zugfestigkeit (N/mm2) 1900 2100 2400 2300 1900 1800 1800 1600 900 700-1200 1000-1300

Hardness (Knopp) 480 500 630 530 530 370 400 160 200 330Fatique resistance - 0 + + + 0 - + - - 0Erosion performance - 0 + + + 0 - 0 - - -

Chemical resistance

Against alkalines - - - 0 0 + + + + - +Against acids - - - - - 0 + + - - 0Application nedium mittelschwer heavy medium heavy medium medium medium light light mittelleicht

Metallic and non ferrous wires

No

vo

fil

MY

No

vo

fil

MY-A

No

vo

fil

MY-S

No

vo

fil

MX

Material group not abrasiveabrasive Filamentabrasive mixture

Abrasive material - Al2O3 SiC SiC/Al2O3

Properties

Micro-fibre multifilament

Micro-fibre multifilaments ae usu-ally manufactured with high den-sities into special OSBORN HDL®

brush constructions.

The filament selection and specifi-cation will be defined and custo-mized to the specific application.

Our application engineers are gladto be further assistance.

Ho

rse h

air

Tam

pic

o

Material group Animal hair Natural fibre

Properties

Natural fibres and animal hair

- very soft bristle with low static charging and excellent sealing effect

- suitable for care-ful cleaning of extremely sensi-tive surfaces, to apply liquids or for brush sea-lings

- very good tem-perature resi-stance as well as electric conducti-vity

- used for dedu-sting, light clea-ning and to apply polishing emul-sions

All information without engagement


43

Technical information8

An optimal brush result is determined by different parame-ters. After selecting the appropriate bristle as well as thebrush design to be used, determining the fill density andtrim length in the process, the focus then turns to the cor-rect operational parameters. In addition, criteria such as

surface speed, brush speed as well as depth of immersionand contact pressure have to be taken into account, andindividually defined under the given framework.

Recommended surface speed / Rpm for different applications

2500

2000

1500

1000

500

0,00

150 200 250 300 350 400

Brush diameter Ø (mm)

Rp

m (

min

-1)

Dedusting (10 m/sec) Cleaning (13 M/sec) Work roll cleaning (15 m/sec) Descaling (18 m/sec)

Kissmark in dependence on depth of immersion and brush diameter Ø

120,00

100,00

80,00

60,00

40,00

20,00

0,00

0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00 4,50 5,00 5,50 6,00 6,50

Depth of immersion (mm)

Kis

sm

ark

(m

m)

Ø 250 Ø 300 Ø 330 Ø 350 Ø 400

Different applications and fill materials require wholly dif-ferent speeds. In turn, the appropriate speed depends onthe roll diameter. On the other hand, the optimum contact pressure can varygreatly according to the brush construction and the fill den-sity. The decisive factor in achieving the required brushresult is the immersion depth, as a brush tool works prima-rily with the bristles and/or the tips of the wire.

The tables in this section should provide approximate val-ues and indications. For detailed information and individualrecommendations, please consult our application engi-neers who will be happy to help.


44

Terminology

APL: Annealing Pickling LineBAL: Bright Annealing LineBL: Brushing LineCAL: Continuous Annealing LineCAPL: Cold Strip - Annealing Pickling Line CCL: Color Coating LineCGL: Continuous Hot-dip Galvanizing Line CL: Cleaning LineCPL: Continuous Pickling LineCRM: Cold Rolling MillDL: Degreasing LineDPL: Descaling Pickling LineECL: Electrolytic Cleaning LineEGL: Electrolytic Galvanizing Line ETL: Electrolytic Tinning Line

FL: Finishing LineGL: Grinding LineHAPL: Hot Strip - Annealing Pickling Line HCM: Hot Continuous Mill HHT: Horizontal Heat Treatment Plant HRC: Hot Rolled CoilsHFM: Hot Finishing MillHRFM: Hot Reversing Finishing Mill HRM: Hot Reserving MillPL: Polishing LinePLTCM: Pickling Section of Combined Tandem Cold MillSL/CCL: Slitting/Cross Cutting LineSPM: Skin Pass MillTLL: Tension Level Line TM: Temper Mill (Kaltwalzgerüst)

Table of surface speeds in metres per sec.

Brush-Ø Surface speed (m/sec.)

(mm)

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

400 477 525 573 621 668 716 764 812 859 907 955 1003 1050 1098 1146 1194390 490 539 588 637 686 735 784 833 881 930 979 1082 1077 1126 1175 1224380 503 553 603 653 704 754 804 854 905 955 1005 1055 1106 1156 1206 1256370 516 568 619 671 723 744 826 878 929 981 1032 1084 1136 1187 1239 1290360 531 584 637 690 743 796 849 902 955 1008 1061 1114 1167 1220 1273 1326350 546 600 655 709 764 819 873 928 982 1037 1091 1146 1200 1255 1310 1364340 562 618 674 730 786 843 899 955 1011 1067 1123 1180 1236 1292 1348 1404330 579 637 694 752 810 868 926 984 1042 1100 1157 1215 1273 1331 1389 1447320 597 657 716 776 836 895 955 1015 1074 1134 1194 1253 1313 1373 1432 1492310 616 678 739 801 863 924 986 1047 1109 1171 1232 1294 1355 1417 1479 1540300 637 700 764 828 891 955 1019 1082 1146 4210 1273 1337 1401 1464 1528 1592290 659 724 790 856 922 988 1054 1120 1185 1251 1317 1383 1449 1515 1581 1646280 682 750 819 887 955 1023 1091 1160 1228 1296 1364 1432 1501 1569 1637 1705270 707 778 849 920 990 1061 1132 1203 1273 1344 1415 1485 1556 1627 1698 1768260 735 808 881 955 1028 1102 1175 1249 1322 1396 1469 1543 1616 1689 1763 1836250 764 840 917 993 1070 1146 1222 1299 1375 1451 1528 1604 1681 1757 1833 1910240 796 875 955 1035 1114 1194 1273 1353 1432 1512 1592 1671 1751 1830 1910 1989230 830 913 996 1079 1163 1246 1329 1412 1495 1578 1661 1744 1827 1910 1993 2076220 868 955 1042 1129 1215 1302 1389 1476 1563 1649 1736 1823 1910 1997 2083 2170210 909 1000 1091 1182 1273 1394 1455 1546 1637 1728 1819 1910 2001 2092 2183 2274200 955 1050 1146 1241 1337 1432 1528 1623 1719 1814 1910 2005 2101 2196 2292 2387190 1005 1106 1206 1307 1407 1508 1608 1709 1809 1910 2010 2111 2211 2312 2412 2513180 1061 1167 1273 1379 1485 1592 1698 1804 1910 2016 2122 2228 2334 2440 2546 2653170 1123 1236 1348 1460 1573 1685 1798 1910 2022 2135 2247 2359 2472 2584 2696 2809160 1194 1313 1432 1552 1671 1790 1910 2029 2149 2268 2387 2507 2626 2745 2865 2984150 1273 1401 1528 1655 1783 1910 2037 2165 2292 2419 2546 2674 2801 2928 3056 3183

Surface speed (v) = Brush diameter (d) x π x speed (n)1000 x 60

Significantly better brush performance is achieved throughthe use of compact brushes and high quality fill materials.Consequently, cooling plays a crucial role, as overheatingcan quickly lead to the bristles becoming brittle causingpremature breakage to occur. The brush cooling facility inthe present plant/line is greatly optimised by correcting andoptimising the angle of spray and flow rate. In turn, this sig-nificantly extends the service life of the rollers. Even theselection of the correct spray jets plays an important role.


Microabrasive brushes and miniatur brushes

Flexible, highly efficient brushing tools for surface finishing of small boresand cross hole deburring.

OSBORN Load Runners®

Load handling systems for precise movement of heavy loads in demandingindustrial applications.

OSBORN TOP

High performance power brushes - Superior range for demanding applica-tions and intense production conditions in industry.

OSBORN Novofil®

Abrasive nylon brushes in Hi Tec filaments, rectangular and round inDiamond, Zirconium, Aluminium Oxide and Silicon Carbide. Available in awide range of grit values.

OSBORN MultiStrip®

Saving thermal energy, reducing the passage of sound, protecting againstinsect and vermin infestation, sealing against dust, dirt, water and smoke,cleaning of industrial and commercial conveying systems.

Our further product range9

45

www.top-brush.com

www.multistrip.de

www.microabrasive-brush.com

www.loadrunners.de


Brushes for weld cleaning

Power driven brushes for the pipeline industry, e.g. cleaning the internal dia-meters of pipe, external cleaning, edge prparation, removal of insulationcoatings, remedial work, cleaning weld seams prior to welding and weldbead deslag.

Multizack system and punched roller brushes

Products for a wide range of applications: Brushes for cleaning, deburring,transporting, sorting, washing, guiding and structuring.

Lippert-Unipol, Polishing and surface finishing tools

The Lippert-Unipol product range contains the following products for anykind of polishing and surface finishing applications: Abrasive non-woven tools, abrasive brushes in various constructions, coa-ted abrasive tools, polishing emulsions as well as polishing buffs and mops,made from cloth, Sisal, Sisal/Cord, Sisal cloth and Notiflex non-wovenmaterials.

OSBORN ATB®

ATB - Advanced Technology Brush System!Disc brushes with abrasive high-tech filaments. ATB disc brushes have filldensity which is 4 times higher than other disc brushes manufactured accor-ding to the conventional method (punched).

OSBORN Novoflex-B®

The flexible honing tool!

46

www.pipelinebrush.com

www.lippert-unipol.de


Su

bje

ct t

o a

lter

atio

ns.

2033

GB

03/

09

OSBORN International GmbH · Manufacturer of Industrial Brushes, Surface Finishing Tools and Load RunnersRingstraße 10 · 35099 Burgwald-Germany · Phone: +49 (0) 64 51 / 5 88-0 · Fax: +49 (0) 64 51 / 5 88-208

eMail: [email protected] · www.osborn.de · www.metallurgy-brush.com

Brazil • China • Denmark • France • Germany • Great Britain • India • Mexico • Portugal • Romania • Spain • Sweden • USA

ISO 9001-2000 Certified Quality System Members of Jason Finishing Group


Documents

Osborn Roller Catalogue