The Ural Engineering Center is ready to offer a comprehensive solution for equipping a ring rolling section, providing a new ring rolling mill at an affordable price, complete with the necessary auxiliary technological equipment and manipulators.
Client:
PJSC "Ruspolimet", Kulebaki, Nizhny Novgorod Region
Year of Implementation:
2015
Project Title:
"Comprehensive Modernization of the H160-S Ring Rolling Mill"
Objective:
The creation of a ring rolling mill, equipped with both radial and axial rolls for the precise rolling of rings made from carbon and alloyed steel grades.
During the project, part of the mill’s equipment was upgraded, which significantly reduced costs for the company (a solution not typically offered by foreign companies). A key highlight of the project was the development of unique software (Registration Certificate No. 2017612564) for the automated ring rolling process, ensuring precision. This work was a nominee for the PRIORITY-2019 national award.
The control system created by UrIC synchronizes the operation of five hydraulic axes (axial and radial rolls, 2 centering rollers, and the axial roller) and three electrical axes (1 radial roller and 2 axial rollers).
The Ring Rolling Section Includes:
- A rotary hearth furnace;
- A loading manipulator;
- The ring rolling mill;
- A ring unloading manipulator;
- A calibration press.
Precision Parameters of Rolled Rings:
| Outer Diameter of the Ring, mm | 350 | 400 | 500 | 630 | 800 | 1000 | 1250 | 1500 |
|---|---|---|---|---|---|---|---|---|
| Tolerance for Dn, mm, ± | 1.0 | 1.25 | 1.5 | 1.75 | 2.0 | 2.5 | 3.0 | 3.5 |
| Tolerance for H, mm, ± | 0.5 | 0.6 | 0.7 | 0.8 | 0.9 | 1.0 | 1.25 | 1.5 |
Scope of Work:
Design:
Development of a complete set of design documentation for custom products, equipment, and components:
- Axial roll;
- New mill frame;
- Mill control system;
- New mill hydraulic system;
- New lubrication system for all mill units and assemblies;
- Cooling system for the axial and radial rolls and equipment;
- Foundations for the mill, auxiliary rooms, cable tracks, and pipeline tunnels;
- Manipulator for unloading finished rings.
Manufacturing and Supply of Parts and Equipment:
- Axial roll;
- New mill frame;
- Manipulator for unloading finished rings;
- Mill hydraulic systems;
- Lubrication systems for all mill units and assemblies;
- Cooling systems for the axial and radial rolls and equipment;
- Foundations for the mill, auxiliary rooms, cable tracks, and pipeline tunnels;
- Existing radial roll equipment from "J.BANNING".
Control System:
An automated control system with instrumentation was developed and implemented for monitoring and controlling the mill’s equipment. The key parameters monitored and diagnosed include:
- Workpiece and finished ring parameters;
- Radial and axial rolling forces;
- Settings for rolling coefficients;
- Diagnostics of all mill systems;
- Control and management of the manipulator.
The automated process control system (APCS) is based on a Siemens CPU S7 - 1516-3 PN/DP controller:
- Number of analog and discrete signals: 855 units;
- Number of automation cabinets: 3 units;
- Central control room (2 operator workstations);
- Instrumentation and control (pressure, temperature, position sensors, laser meters, etc.).
Software:
The APCS team developed and implemented proprietary software.
Electrical Equipment:
- Installed power: 1200 kW
- Number of electric drives: 23 units
- DC motors: 500 kW – 1 unit, 200 kW – 2 units, speed controlled
Installation and Commissioning:
- Reconstruction of the radial roll components:
- Installation of independent drives for the right and left centering rollers;
- Installation of a rotary drive for the mandrel shaft, mechanization of mandrel shaft installation and removal;
- Repair of the mandrel shaft cassettes;
- Repair of the main shaft cassette.
