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Elanders Novum 2003, Vsters 3AST002515

ABB IndustrialIT
Interstand Dimension Control, IDC

ABB IndustrialIT
Interstand Dimension Control, IDC

AC800M

AC800

AC450

HPC / VIP
ProfiBus / Discret I/O
MB300

MP200

Alien

Ethernet TCP/IP / UDP


U Pad
Gateway
Web server

U Gauge

- takes your profile mill into a new dimension

ABB Automation Technologies


Hot Rolling Mills
SE-721 67 Vsters, SWEDEN
Tel +46-21 34 00 00
Fax: +46 21 18 17 24
www.abb.com/metals

WLAN

Touch
Panel

Operate IT
UG tool

ABB IndustrialIT
Interstand Dimension Control

a concept for dimension control in profile mills


Closer tolerances
Higher yield and availability
Simplified operation
Installed U Gauges

Traditional rolling methods in rod and


bar mills are based on minimum tension
control and loop control. These methods
are not sufficient to meet the increasing
market demands on quality and tolerance.
Minimum Tension Control, derived from torque measurements, freezes the speed relationships to the front end demands by assuming
a constant dimension and temperature profile
along the bar. The dimensional tolerances of
billets normally lie in the range of 2 %. The
temperature fluctuations from head to tail can
be as much as 20 to 50 C, depending on the
furnace condition and the temperature drop
between the furnace and the first mill stand,
which results in a colder tail end. In reality,
these kinds of variations require Loop Control
to take care of the mass flow variation.
However, Loop Control cannot control the
spread in the roll gap that causes variations
in the dimensions, thus affecting the final
tolerances.

IDC provides a tool for the continuous


improvement and control of the rolling
process and especially the tolerances
from head to tail of round long products.
The IDC concept is based on the latest developments in process control and wireless communication and consists of:
- The U Gauge sensor for on-line measurements from head to tail.
- The TCP/IP gateway with web server and
interface for external log.
- The UG Tool, a PC-based operator and
maintenance interface.
- The U Pads, specially developed user interface for Pocket and Tablet PCs working
with WLAN.
- The AC800M controller for communication
and process control.

Final U Gauge control configuration

IDC concept

U Gauge Sensor

Operator Interface

Mill Configuration

IDC is applicable to both old and new profile


mills. It is easy to integrate IDC into an existing
automation system via a network or digital/
analog I/O and it can be configured as a
control or measuring system. Installation and
commissioning can take place during normal
production.

The U Gauge is based on ABBs patented


Pulsed Eddy Current Technology and does not
have the limitations and drawbacks associated
with conventional eddy current technology. It
ensures that measurements are performed
with exceptionally high accuracy, also under
very difficult environmental conditions.

By observing the graphical displays, the rollers


get early warnings of abnormalities in the rolling and can make the necessary adjustments.

A good strategy to implement IDC is first to


install as many sensors as possible in the mill
in order to identify and find problems related
to dimension, temperature and pass design.
Experience has shown that problems are
found and can be addressed, resulting in a
reduced need for sensors after each stand.

AC800M

AC800

HPC / VIP
ProfiBus / Discret I/O
MB300

MP200

AC450

Alien

Ethernet TCP/IP / UDP


U Pad
Gateway
Web server

IDC Control

Touch
Panel

WLAN
U Gauge

Key dimensions like height, width, area, resistivity, temperature and position are measured
in less than one millisecond. Height, width,
position, temperature and gauge status are
communicated via a TCP/IP gateway. The
gateway also includes a web server for data
and maintenance access via standard web
browsers.

It is essential that the human system interface,


HSI, is designed with the user in mind and
therefore the IDC operator interfaces are divided into two categories, one for the control
room and main operator and the other for the
mill crew on the floor.

Operate IT
UG tool

IDC controls the mass flow with the help of


width, height and speed control of the rolled
material. The width is controlled from head to
tail by means of interstand speed changes,
while the height is compensated for roll wear
between bars.

IDC benefits
- Tighter tolerances head to tail.
- Improved
Product quality
Yield
Availability
- Fast product and dimension changes
- Early indication of abnormal mill
conditions
- Operator tool to facilitate process
understanding
- More consistent mill setup
- Improved pass schedules

The main operator interface includes schedule, setup, analysis and maintenance displays.
The mill crew interface can be mounted in
local pulpits or be incorporated in hand-held
Pocket and Tablet PC working with the
WLAN.
U Pad
Touch
Panel
WLAN

An Automatic Dimension Control package,


ADC, is available as an option to the IDC concept. The ADC system is used after the final
mill stand to control the diameter and ovality.

The first step to investigate the mill could be


done by the customer himself by just installing
a stand-alone Measuring system.

Later on, this system can be upgraded to a


Stand-alone Control system or an Integrated
Control System with the addition of the IDC
control system based on AC800M controllers.

Result
The final IDC control configuration can be
optimized to a few strategic positions in the
mill. With an optimized IDC control configuration as described above, a 20 mm round bar
can be rolled to tolerances as below.