Technologies and Automated Control Systems for Rolling and Hardware Production Processes
Development of the Rolling Mill Practices for Roughing Mills
Since 1992 RPC "Donix" has been developing new rolling patterns and ingot drafting schedules as well as roll pass designs for roughing mills, allowing to reduce the discharge coefficient of the production processes.
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Multistrand Rolling-Slitting (MRS) is a Non-Conventional Technology of Rebars and Merachnt Bars Production
The multistrand (double-strand) rolling-slitting technology is based on fundamentally new patterns of stock slitting: slitting by means of controlled break, shear, mutual shift in sloping passes etc.
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The System of Control over the Rolled Stock Cutting Process on a Continuous Billet Mill (Version 1)
The system's purpose is to minimize the rolling-mill scrap (crops) and the amount of random bar lengths at the exit from the main line of a continuous billet mill, as well as to keep a reliable record of the produced rolled stock.
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The System of Control over the Rolled Stock Cutting Process on a Continuous Billet Mill (Version 2)
The system's purpose is to minimize the rolling-mill scrap (crops) and the amount of random bar lengths at the exit from the main and bypass line of a continuous billet mill, as well as to keep a reliable record of the produced rolled stock.
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Firmware System for Data Acquisition and Control over the Main Drives Operating Parameters on Roughing and Continuous Billet Mills
The system increases the efficiency of the attendants work, speeds up emergency situations and standard rolling process disturbances analysis. The above-mentioned effect is obtained as a result of continuous registration and visualization of an extended number of parameters, measurement devices application and the results presentation in a form, suitable for analysis.
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Digital Integrated System of Control over the Main Drive of the Rolling Mill 1300 in the Blooming Shop of KRSIMMW "Krivirozhstal"
The system controls the roll motors of a reversing roughing mill. The principle of the system's configuration can be used for similar control systems on rolling mills of other types.
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Automated Control System for Ingot Heating
The system's purpose is to provide automatic ingot heating in the soaking pits of roughing mills with a view to reducing power consumption during the roughing mill unstable operation (by means of automatic change for energy-saving process charts), as well as increasing the maintainability of the equipment in the soaking pits division of the roughing mill (by means of eliminating the risk of occurrence and development of unstable and emergency modes of operation).
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System of Control over the Rolling Mill Practice and Speed Schedules of a Roughing Mill
The system increases maintainability of the roughing mills equipment by means of eliminating the risk of occurrence and development of unstable and emergency modes of operation.
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System of Control over the Parameters of Main Electric Drives on Reversing Mills
Field of application: duo reversing mills.
Purpose: to improve maintainability of rolling stands equipment due to prevention of unstable and emergency schedules; to reduce downtimes.
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Automated Tracking System for a Continuous Rolling Mill
Continuous rolling mills are main suppliers of finished products of the metallurgical industry. To satisfy the requirements of the market, the range of their products must be as wide as possible within the processing capabilities. This requires frequent mill set-up and complicates preproduction process. Application of modern hardware allows to introduce automation into the roll pass design and mill set-up processes. Engineers of RPC "Donix" developed and introduced into commercial operation an automated tracking system for the production process on the continuous rolling mill 250 in Queenborough (Great Britain).
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Integrated Measuring System for a Workpiece, Moving along the Processing Line of a Rolling Mill
The system ensures rational workpiece cutting on the shears and keeps automatic record of the quality metal weight in the roughing mill.
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Information-Calculating System "The Operator's Adviser"
The system works out recommendations regarding the modes of the ingot heating in the soaking pits of the roughing plants under conditions of the rolling mill stable operation, as well as during the equipment downtimes, with a view to increasing the operating efficiency of the soaking pits division.
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Tracking System for Slabs Rolling Process on a Mill Complex "Roughing Mill — Continuous Hot Rolling Mill"
The automated control system sorts out slabs (blooms), which are sent to transit rolling, according to the power consumption for metal deformation per rolling cycle, in order to achieve energy savings and increase the process safety.
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System for Rational Workpiece Cutting on the Shears of Roughing Mills
The system's main functions are:
- to calculate the rational plan of the workpiece cutting into slabs;
- to carry out contactless measurement of slab lengths;
- to calculate the slab weight;
- to identify the slabs and to assign unique codes to them; the code contains heat number, workpiece (ingot) number, number of the slab obtained from the workpiece;
- to generate information data base.
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Automated System of Control over the Heating Modes of Soaking Pits
The system’s purpose is to ensure automated control over the process of ingots heating in the soaking pits of roughing mills, as well as to provide the operational and technological staff with proper information.
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Improvement of Continuous Furnace Heating Modes due to Modernization of the «Pipe-in-Pipe» Burners
Fuel rate reduction is obtained due to the reduction of the overall air consumption coefficient of the furnace down to the values not exceeding 1,1. Its values in the welding zone are significantly lower (down to 1,04). As a result the oxidizing ability of the furnace gases in the working space of the furnace decreases which leads to the reduction of the metal waste.
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System of Control over the High-Speed Wire Blocks Setup (ESCB)
RPC «Donix» developed an electronic system of control over the high-speed wire mill blocks setup (ESCB), including control over the rolling mill kinematic parameters and monitoring of the entry guide rollers operation. The system is based on the measurement of angular speeds of the block entry guide rollers.
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Complex Software for the Automated Control Systems of the Controlled Cooling Unit for Sheet Products.
RPC «DONIX» developed a complex program software for the automated control systems of laminar controlled cooling units (CCU) on hot plate and strip rolling mills.
A simulation model of the control system of the CCU for plate products working in real-time mode was developed in order to check and preset the software.
The developed program package can serve as a base for the creation of an automated control system for almost any laminar cooling unit for sheet products.
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Automated Position Control System for the Screw-Down Structure of Vertical Rolls of Slabbing Mill “1150”, ACS “APCS VRSDS 1150”.
Purpose of the automated position control system for the screw-down structure of vertical rolls of the slabbing mill (ACS "APCS VRSDS") is to ensure automated control over the width of the rolled slabs to obtain minimal scrap edges during subsequent transit rolling of the obtained slabs on the hot wide-strip mill.
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Upgrade of Control System for the Furnace Section of 150 Mill of CJSC «Makeevka Metallurgical Works»
Purpose: To replace the out-of-date equipment of Level I automation. Development and implementation of Level II automation for automated control over the thermal conditions depending on the rolling rate and steel grade, as well as automation of such subsystems of the furnace section as the waste-heat boiler and evaporation cooling system based on the new control system.
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