keeping your process at the centre of everything we do · abb systems platform • ac800 pec...
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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
Process Engineering Services
KEEPING YOUR PROCESS AT THE CENTRE OF EVERYTHING WE DO
• 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
Process Engineering 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
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 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
Process Engineering Services
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
Process Engineering Services
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
Process Engineering Services
• 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
Level 1 Process Control Systems
KEEPING YOUR PROCESS AT THE CENTRE OF EVERYTHING WE DO
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 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
Level 1 Process Control Systems
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
Level 1 Process Control Systems
Top flatness rating from can manufacturers Tuning Analysis Assessment
Level 1 Process Control Systems
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
Level 1 Process Control Systems
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
Level 2 / 3 Solutions
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
Level 2 / 3 Solutions
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
Level 2 / 3 Solutions
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
KEEPING YOUR PROCESS AT THE CENTRE OF EVERYTHING WE DO
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.
Level 2 / 3 Solutions
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.
Level 2 / 3 Solutions
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
Level 2 / 3 Solutions
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
Level 2 / 3 Solutions
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
Level 2 / 3 Solutions