Professional Documents
Culture Documents
WALDRICH SIEGEN
Heavy Duty CNC Roll Grinding Machine
ProfiGrind 2500
BOKARO STEEL PLANT
Attn.: Mr. B.B. Jha, AGM Design Bureau
Hot Strip Mill
Bokaro Steel City 827004
INDIA
Date:
Project
Responsibility:
GENERAL INFORMATION
Table of Contents
1
ACCESSORIES..............................................................................................................................27
3.1
B-axis ..................................................................................................................................27
3.2
Eddy Current System (EC) .................................................................................................29
ACCURACIES ................................................................................................................................31
TECHNICAL SPECIFICATION
TECHNICAL DESCRIPTION
To assist you in your selection of a roll grinder supplier, below is a listing of benefits
of WALDRICH SIEGEN engineering and design features:
1.1
Beds
1.2
Details of Design
Benefits
Headstock
Headstock
Details of Design
Benefits
TECHNICAL SPECIFICATION
1.3
Counterstay
Counterstay
TECHNICAL SPECIFICATION
1.4
Details of Design
Benefits
Details of Design
Benefits
TECHNICAL SPECIFICATION
1.5
Details of Design
Benefits
Hydrostatic
TECHNICAL SPECIFICATION
1.6
Grinding Carriage
Z
B
Details of Design
Benefits
Longitudinal feeds :
6 - 9000 mm/min.
Surface cutting
45m/sec.
speed
up
to
TECHNICAL SPECIFICATION
Details of Design
Benefits
Details of Design
Benefits
TECHNICAL SPECIFICATION
Details of Design
Benefits
Time-saving, operator independent operation provides a soft contact with the roll.
Zero backlash, due to the electrical bracing of the master/slave mode of the servo
drives.
Improved smoothness of running by deletion of the worm drive and shortening of
the drive track.
Higher feed rate in Z-direction (up to 12
meter/min) cycle time improvement.
The symmetrical arrangement of the
motors outwards on the lower carriage
improves the stiffness and avoids tilting
at the reversing points of the wheel.
TECHNICAL SPECIFICATION
1.7
10
TECHNICAL SPECIFICATION
Details of Design
Benefits
Highest accuracy.
Automatic measurement.
The outer measuring arm is operated during the grinding process to monitor stock
removal and roll diameter.
Reliability.
Versatility.
Process integration.
11
TECHNICAL SPECIFICATION
Details of Design
Benefits
1.7.1
Measurement of shape
Measurement of eccentricity
Measurement of out-of-round condition
Measurement of diameter
Measurement during the grinding process
Automatic grinding according to prorated stock removal
Automatic grinding according to prorated diameter of roll
Dual (mate) grinding of work roll pairs
Optimization grinding by comparison of rated and actual values
Automatic alignment of the roll to be parallel with the carriage bed (optional)
12
TECHNICAL SPECIFICATION
13
TECHNICAL SPECIFICATION
Overview of PGC 10
2.1
14
TECHNICAL SPECIFICATION
The I/O (input/output) is made up out of a daisy chained string of I/O modules, which
allows decentralized placing of these modules anywhere on the machine, drastically
reducing wiring. Fiber optical communication allows for extremely fast updates,
while interference from conventional copper wiring is eliminated. The update rate of
this so-called Light Bus is over 1 MHz.
PGC 10: Configuration Screen for all Axis (Totally Open System)
The software platform chosen is Microsoft Windows XP, with a real time extension.
This stable operating system is widely used and lots of software tools are available.
The operator interface (or GUI, Graphical User Interface) is specifically designed for
roll grinder applications, while the look and feel of the previous generation of PGC
May 31, 2006
15
TECHNICAL SPECIFICATION
16
TECHNICAL SPECIFICATION
2.2
Benefits
Controller
Type
Full integration of
Operation
17
TECHNICAL SPECIFICATION
Details of Design
Benefits
In-Process corrections
Thanks to the computer's fast rate of reaction, when measuring during grinding, an
actual correction curve will be calculated
and actuated during each of the return
grinding strokes.
Grinding to tolerance
Upper and lower tolerance curve are preselectable; the shape grinding process is
automatically stopped once the actual
curve lies within the tolerance range and for
example the removal target is reached. The
next cycle then immediately continues.
Roll shape creation by the concave/convex,
continuous path CNC grinding control.
18
TECHNICAL SPECIFICATION
Details of Design
Benefits
Auxiliary panel
Software programming
Extended by
19
TECHNICAL SPECIFICATION
Details of Design
Benefits
Help Function
Functions
20
TECHNICAL SPECIFICATION
Details of Design
Benefits
By use of
Note:
It is obvious that all roll measuring functions require choosing the roll measuring and
inspection system if not already included in the basic scope of supply.
In case of fully automatic roll grinders, sometimes automatic roll loading / unloading
systems are required. We have developed different systems including roll storage
racks.
2.3
Benefits
21
TECHNICAL SPECIFICATION
2.3.1
Details of Design
Benefits
Closed loop control of the axes of headstock and carriage to allow thread cutting of
all required pitches
Grinding of the outer surface of a shell concentrically to its inner bore, by use of correction values.
2.3.2
Extended Diagnostics
The standard fault system provides excellent detection for over 200 possible faults
on the machine. An optional extended diagnostics system provides additional features that complement the standard fault detection system.
The extended diagnostics enhance the fault detection system by providing aids to
maintenance personnel when a fault is detected and extending the fault detection to
time-dependent failures which are not detectable by traditional fault detection systems.
In operation, this provides the extended features of displaying the complete logic
associated with the detected fault. This aid to maintenance provides on-line information in relay ladder form (graphically displayed on the operator's TFT). This means
that, once failures are detected, the time to resolve the problem is reduced.
Additional aids include tracing of selected inputs, outputs and flags and also the ability to scroll through the relay ladder logic. A clear text description and color indication of status of inputs, outputs and flags is also provided.
2.3.3
Scope View
Via a scope view system it is possible to view I/Os and flags as well as variables. In
the logbook the user actions, overrides, messages, faults PLC-messages and sequential function carts (SFC) messages are logged.
2.3.4
22
TECHNICAL SPECIFICATION
2.4
Monitoring services
Storage capabilities
SPC-capabilities
Roll history built-up
Roll tracking, scheduling
Full up- and downloading
Program back-up service
Your host (main frame) computer preferably through central roll shop computer
2.4.1
Benefits
Electronically range
Sinus curve
10 mm on radius
26 - 180 degrees angle section
23
TECHNICAL SPECIFICATION
Details of Design
Benefits
Compound curves
Profile value:
a1: ..........................E6
a2: ..........................E9
ax:...........................Ex
a7: ..........................E24
Barrel start: ............mm
Barrel end: .............mm
Mirror:.....................yes/no
One-button mirror function for tope and
bottom rolls
Arc grinding
Empirical curves
24
TECHNICAL SPECIFICATION
2.4.2
Benefits
Crowning range
25
TECHNICAL SPECIFICATION
Details of Design
Benefits
Adaptive control.
In case of adequate roll inspection
system and automatic grinding package
26
TECHNICAL SPECIFICATION
ACCESSORIES
3.1
B-axis
For swiveling of the grinding wheel face for fast and precise CVC grinding.
Developed, designed and patented by WALDRICH SIEGEN, the B-Axis offers the
possibility to use a roll grinding machine at highest accuracy, exceptional surface
quality, reduced wheel wear and to achieve shortest grinding times. One reason for
its development was the high edge-wear when grinding roll curves with a large variety of diameters. (CVC-curves for example)
Technical Advantages of the B-axis used on heavy Roll Grinders (Principle Sketch)
27
TECHNICAL SPECIFICATION
By using the B-axis WALDRICH SIEGEN roll grinding machines are capable to position the grinding wheel always vertically to the corresponding curve tangent, which
offers the following advantages:
Increase grinding machine performance in a cold rolling mill by up to 30 %
Reduced grinding times by using maximum machine performance
Reduced wear of the grinding wheel (and possibility to use harder wheels) and
increase of the grinding wheel contact area
Increase of the roll shape accuracy and simultaneous improvement of the surface quality.
Technical Data
Swiveling angle of grinding wheel to accommodate generated line
Swiveling angle...................................................................
deg.
0,225
Feedrate .............................................................................
deg./s
0,0833
Nm
rpm
1 - 4000
Resolution...........................................................................
arcs
0,858 x10-5
28
TECHNICAL SPECIFICATION
3.2
3.2.1
3.2.2
29
TECHNICAL SPECIFICATION
The effective width of the eddy current inspection head is 40 mm (optional 13 mm).
The eddy current roll inspection can be carried out during the grinding process. With
several passes during the grinding process the complete surface of the roll is
checked.
30
NOTES
ACCURACIES
Manufacturing and installation of our grinders are performed according to WALDRICH SIEGEN geometric acceptance regulations TKA 121 00 002 CP per German
DIN and ISO Standards.
mm
0,001
Eccentricity .........................................................................
mm
0,002
0,001
0,0025
0,002
31