Keeping Your Process at the Centre of Everything We Do 1 op - - PowerPoint PPT Presentation

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Keeping Your Process at the Centre of Everything We Do 1 op - - PowerPoint PPT Presentation

Aug 26, 2023 349 likes •576 views

Keeping Your Process at the Centre of Everything We Do 1 op optimAl pr process ss technology ltd ltd. Process Automation Specialists DRIVING PERFORMANCE Process Engineering Level 1 Process Services Control Systems Level 2 / 3

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Keeping Your Process at the Centre

  • f Everything We Do

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DRIVING PERFORMANCE

Process Automation Specialists

Process Engineering Services Level 1 Process Control Systems Level 2 / 3 Solutions

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  • ptimAl pr

process ss technology ltd ltd.

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Keeping Your Process at the Centre of Everything We Do

Process Engineering Services

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Control system performance analysis Bespoke controller designs Control system optimisation Mill vibration analysis

Specialists in Machine Dynamics & Control

Comprehensive set of dynamic mill models - the basis for the delivery of a range of services

Process ss Eng Engineering Ser Services

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SLIDE 5 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 CHOCK WORK ROLL CHOCK WORK ROLL CHOCK WORK ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP 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 CHOCK WORK ROLL CHOCK WORK ROLL CHOCK WORK ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK BACKUP ROLL CHOCK NEGATIVE BEND SERVO NEGATIVE BEND SERVO POSITIVE BEND SERVO POSITIVE BEND SERVO

BEND CONTROLLER BEND CONTROLLER

MEASURED PRESSURES MEASURED 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 Exit Gauge Reference ExitGauge Exit Gauge Measurement Exit Gauge ( Microns ) [Time,EntryGauge] Entry Gauge Entry Gauge ( Microns ) Exit Gauge Reference Exit Gauge Measurement CONTROLLER

Speed increase 25% Gauge improvement > 20%

From mill audits through controller design to full optimisation Model based controller design Model based optimisation Implementation on existing platforms Hot mills Tandem cold mills Single stand cold & foil mills

Gauge Control Flatness Control Productivity Process Control Audits Process ss Eng Engineering Ser Services

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Instrumentation Design Services Mill Duty 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 ss Eng Engineering Ser Services

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FLATNESS THICKNESS

板形 厚度

FLATNESS THICKNESS

板形 厚度

Ce rtific ate o f training

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This is to certify that

__________________

has successfully completed the 1 day training course:

Introduction to Cold Rolling of Aluminium Introduction to Cold Rolling of Aluminium for Operators for Operators

Presented by: Presented by:

  • ptimAL process technology limited
  • ptimAL 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

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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 ss Eng Engineering Ser Services

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Keeping Your Process at the Centre of Everything We Do

Le Level 1 1 Process ss Control Systems

Level 1 Process Control Systems

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Controller design & optimisation using optimAl dynamic models Systems platform selection based on customer requirements ABB GE Siemens Single stand cold & 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

KEEPING YOUR PROCESS AT THE CENTRE OF EVERYTHING WE DO Le Level 1 1 Process ss Control Systems

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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 Exit Gauge Reference ExitGauge Exit Gauge Measurement Exit Gauge ( Microns ) [Time,EntryGauge] Entry Gauge Entry Gauge ( Microns ) Exit Gauge Reference Exit Gauge Measurement CONTROLLER

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5 dB Stimulus --> Position Reference 10

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50 100 150 Frequency Hz Degrees

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

Le Level 1 1 Process ss Control Systems

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Total Process Support Outstanding Results 3 Stand Cold Tandem 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

  • ptiMize 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

Top flatness rating from can manufacturers

Tuning Analysis Assessment

Le Level 1 1 Process ss Control systems

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Extensive Engineering Interfaces Level 2 from optimAl 3 Stand Cold 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 Le Level 1 1 Process ss Control Systems

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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

Le Level 1 1 Process ss Control Systems

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Keeping Your Process at the Centre of Everything We Do

Level 2 / 3 Solutions

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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

Le Level 2 2 / 3 3 Sol Solutions

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Automatic Process Diagnostics for Metals Rolling & Processing

Production ROI

$ ¥ €

✓ Reduced scrap ✓ Increased yield ✓ Increased productivity ✓ Fast detection of process problems ✓ Material and machine performance tracking ✓ Better use of valued process engineering resources Delivering real payback

Plant Management & Supervision Process Engineering & Quality Control

Le Level 2 2 / 3 3 Sol Solutions

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Casting Furnaces Hot Mills Cold Mills Foil Mills Levelling Lines Coating Lines Slitting Lines Testing

Casting Finishing

Automatic tracking of material & machine performance throughout the entire process

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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

Le Level 2 2 / 3 3 Sol Solutions

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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

  • ptimAl support for integration with your level 1 systems

Learned Rolling Force Learned Roll Bend

Le Level 2 2 / 3 3 Sol Solutions

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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

  • ptiMize process diagnostics for hot mills

Automated performance monitoring Detailed process analysis tools Web based production reporting

Le Level 2 2 / 3 3 Sol Solutions

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Keeping Your Process at the Centre of Everything We Do

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