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Foil and Cold Mill Retrofit

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Foil Mill , Cold Rolling Mill with Uncoiler/ Pay Off, Mill Stand, Recoiler, Backup Roll ,Work Roll and AGC Control

𝗙𝗼𝗶𝗹 𝗮𝗻𝗱 𝗖𝗼𝗹𝗱 𝗥𝗼𝗹𝗹𝗶𝗻𝗴 𝗠𝗶𝗹𝗹 𝗥𝗲𝘁𝗿𝗼𝗳𝗶𝘁.
What improvement on production, operation and maintenance that can be made?

Foil mill and Cold mill is used to reduce thickness of the metal like aluminum with consistent in thickness and quality.

Most of the mill is controlled by DC Drive. The operator desk may still use analog meter, potentiometer and thumbwheel switch for operation. Normally the mill has separate control to control thickness, and some still operated manually by operator.

On foil mill (aluminium), thickness adjusted by controlling tension or speed. At Cold mill by controlling roll gap and load force. Roll bending and oil coolant spray is used to adjust the sheet flatness.

Beside tension, thickness, width and speed, foil mill has additional setting on draft ratio and extrusion to properly calculate diameter and control the tension.

Mill consist of Pay off Reel/ uncoiler, Mill, and Recoiler. Other control include oil mist and coolant filter system. Cold Mill has belt wrapper, coil car etc.
As the coolant oil easy to catch fire from roll friction etc, mill also equipped with fire extinguisher system

𝗛𝗲𝗿𝗲 𝗮𝗿𝗲 𝘀𝗼𝗺𝗲 𝗽𝗼𝘀𝘀𝗶𝗯𝗹𝗲 𝗶𝗺𝗽𝗿𝗼𝘃𝗲𝗺𝗲𝗻𝘁 𝘁𝗵𝗮𝘁 𝗰𝗮𝗻 𝗯𝗲 𝗺𝗮𝗱𝗲 𝗳𝗿𝗼𝗺 𝗺𝗶𝗹𝗹 𝗿𝗲𝘁𝗿𝗼𝗳𝗶𝘁 :

– 𝗜𝗺𝗽𝗿𝗼𝘃𝗲𝗱 𝗾𝘂𝗮𝗹𝗶𝘁𝘆 𝗼𝗳 𝘁𝗵𝗲 𝗽𝗿𝗼𝗱𝘂𝗰𝘁 𝗮𝗻𝗱 𝗿𝗲𝗱𝘂𝗰𝗲 𝘁𝗵𝗲 𝗿𝗲𝗷𝗲𝗰𝘁𝗲𝗱 𝗽𝗿𝗼𝗱𝘂𝗰𝘁. Adding and integrate AGC (Auto Gauge Control) to control thickness along with precise tapered tension control, will maintain consistent thickness and tension.

– 𝗘𝗻𝗲𝗿𝗴𝘆 𝗲𝗳𝗳𝗶𝗰𝗶𝗲𝗻𝘁. Traditionally, Motor field on uncoiler/ recoiler proportional to coil diameter. Using different strategy on motor field control, it can be optimized to save energy while maintaining the accuracy.

– 𝗥𝗲𝗱𝘂𝗰𝗲𝗱 𝗰𝗮𝗯𝗹𝗲 𝗺𝗮𝗶𝗻𝘁𝗲𝗻𝗮𝗻𝗰𝗲 𝗮𝗻𝗱 𝗰𝗼𝘀𝘁. Troubleshooting many cable, not easy to do. Replace it with one ethernet cable that connected to Remote I/O.

– 𝗥𝗲𝗱𝘂𝗰𝗲𝗱 𝗵𝗮𝗿𝗱𝘄𝗮𝗿𝗲 𝗺𝗮𝗶𝗻𝘁𝗲𝗻𝗮𝗻𝗰𝗲 𝗮𝗻𝗱 𝗰𝗼𝘀𝘁. Replace old potentiometer, meter and thumbwheel switch to Panelview. This not only reduce components but also total PLC module that is used.

– 𝗜𝗺𝗽𝗿𝗼𝘃𝗲𝗱 𝘀𝗮𝗳𝗲𝘁𝘆 𝗶𝗻𝘁𝗲𝗴𝗿𝗶𝘁𝘆 𝗮𝗻𝗱 𝗿𝗲𝗱𝘂𝗰𝗲𝗱 𝘁𝗿𝗼𝘂𝗯𝗹𝗲𝘀𝗵𝗼𝗼𝘁𝗶𝗻𝗴 𝘁𝗶𝗺𝗲. Troubleshooting hardwire emergency circuit could be very hard and troublesome. Replace with safety I/O that connected to safety ethernet will reduce maintenance time tremendously.

– 𝗘𝗮𝘀𝗶𝗲𝗿 𝘁𝗼 𝘁𝗿𝗼𝘂𝗯𝗹𝗲𝘀𝗵𝗼𝗼𝘁 𝗲𝘃𝗲𝗻 𝗿𝗲𝗺𝗼𝘁𝗲𝗹𝘆. Online through ethernet to connect to Control Logix and Powerflex DC drive with build in very fast trend to catch glitch and intermittent fault.

– 𝗘𝗮𝘀𝗶𝗲𝗿 𝘁𝗼 𝗼𝗽𝗲𝗿𝗮𝘁𝗲. Setup and operate easily using panelview. Controller will automatically adjust thickness and tension, until coil is finished.

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