RETROFIT OF THE ELECTRONIC SYSTEM AND SOFTWARE OF THE SIDERFORGEROSSI RADIAL-AXIAL ROLLING MILL
Analysis, design, implementation and commissioning: the complete package offered by Project Group today enables a complete and customised solution to be found according to customer needs.
Read the full article to discover the details of the project carried out at Siderforgerossi Group SpA on the Radial-Axial Rolling Mill 160/125 using our RollingCAD software package.
THE CUSTOMER’S REQUEST
Siderforgerossi Group SpA, a company with a century-long history and experience in the process of rolling steel rings and non-ferrous alloys, with 600 employees in Italy alone and production of over 120,000 tonnes/year, contacted Project Group to carry out an analysis of the plant and improve performance in response to increasingly demanding market requirements.
Project Group’s engineers conducted a preliminary analysis and thorough inspection of the rolling mill in all its parts, and a Retrofit of the electronic system and software was agreed upon.
ANALYSIS, DESIGN, IMPLEMENTATION AND COMMISSIONING: THIS IS THE COMPLETE PACKAGE OFFERED BY PROJECT GROUP.
THE 5 STEPS THAT IMPROVED CONTROL OF THE SIDERFORGEROSSI ROLLING MILL
Drawing on our experience and know-how, we were able to intervene to improve rolling control by updating it to the most recent technologies in the sector.
After listening to the customer’s needs and inspecting the plant, 5 steps for carrying out the revamping were defined:
- A wired electrical switchboard was supplied containing the latest versions of hardware and firmware components, using commercial-type components that are easy to source in the future.
- The operator workstation was revised to promote simple and intuitive process management through the implementation of LCD screens, touch panels, joysticks, handwheels and adjustment knobs, all ensuring ergonomic positioning of the main components based on operator input.
- The triangulation laser for measuring ring diameter was replaced with a commercial-type component and a vertical movement platform was installed.
- The supervision system and electronic components were updated to comply with the Industry 4.0 plan.
- The proprietary software “RollingCAD” was installed for management of the rolling process.
THE HEART OF THE MACHINE
In synergy with the control software, RollingCAD, which represents the “heart” of the machine, a series of extraordinary advantages were achieved.
The proprietary RollingCAD software package, entirely developed by Project Group engineers, enables complete management of the rolling process and simulation of the cycle.
Here are the most important strengths of our Software:
- DESIGN rolling curves in an assisted manner.
- REVISE/MODIFY parameters on and offline.
- IMPORT/EXPORT data from external calculation systems.
- 3D PROCESS SIMULATION.
- RAPID SIZING of the preform.
WHAT DOES THE SOFTWARE DO? DISCOVER THE ADVANTAGES!
- Enter both the dimensions of the rolled ring and the preform and quickly visualise their shape, proportions and compatibility of the entered data via 3D graphics.
- Automatically calculate both the rolling curve and the proposed preform to obtain a specific rolled ring.
- Graphically draw with the mouse the rolling curve and other main parameters, with the ability to manage all the peculiarities of the rolling process also with other materials such as titanium or superalloys.
- Perform graphical simulation of the rolling process with 3D visualisation of the machine’s tooling in operation and the ring’s growth.
- Display the “actual” trends acquired during the rolling process.
- Insert correction curves based on prior corrections already carried out.
- Programme the distribution of excess volume (or volume deficit) on the outer or inner diameter of the ring, in programmable proportions.
- Set the production strategy according to needs and parameters.
- Measure the current ring values and production parameters in real time.
- Automatically save to file the data acquired for each rolled ring.
- Perform the machine calibration and compensation procedure.
- Set up the connection with other external design systems.
By updating the SCADA supervision system, the possibility was obtained to have a general overview of the plant under control, displaying all main operating parameters in real time through virtual instrumentation.
Furthermore, the status of manual correctors and automatic regulators can also be displayed!
The rolling mill can thus operate in three modes – manual/semi-automatic/automatic – and continue to roll rings of different geometries, profiles and any type of material, such as titanium and aluminium alloys (with different peculiarities in process management).
Finally, the plant is remotely tele-controllable, enabling maintenance and diagnostic interventions in full compliance with all cybersecurity principles.
Naturally, the entire intervention was carried out in conformity with Industry 4.0 requirements.
”It was not easy to meet the required specifications, primarily oriented towards optimising the production process, while adapting the control and plant management systems to current regulations.
Once again, however, we brilliantly achieved the objective, thanks to the experience and know-how of the team, and to consolidated solutions such as our proprietary software "RollingCAD". We completed the work on schedule, achieving the highest customer satisfaction, which is always our top priority.
Mirco CasiniProject Manager laminazione e automazione
