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Automation Products

Mill View System
The  Mill View System software package is an analytical tool that uses colorful graphic displays to highlight specific mill process parameters and allows for the examination of setup data for each billet rolled.  Mill operators and rollers can assess causes of cobbles, improve mill setup practices (compare existing setups to actual), and predict equipment deterioration.

Mill Control System

New speed control concept for rolling of long products  
A PLC-based rolling mill speed control system provides high-performance mill setup and control functions for the processing of long products in a continuous rolling mill.

The Mill Control System comes complete with a real-time PC-based simulator for preliminary mill tune up and operator training.  Powerful Windows NT-based HMI screens with built-in help menus help the operator be more effective in processing tonnage.

Benefits: 

  • Switchover retrofit for existing systems
  • Powerful and reliable PLC-based control system
  • Easy to understand and maintain program
  • User-friendly and functional HMI screens
  • Fully tested prior to commissioning on a Virtual Mill Simulator
  • Flexible configuration of working stands
  • Short commissioning period
  • Rolling schedules server is included
  • Installation engineering is included
  • Training is included
  • Remote support via direct link to SESA offices
  • Most competitive price

Features: 

  • Mill configuration setup
  • Mill preparation and start up
  • Cascade speed control
  • Interstand tension control utilizing Neuro-Fuzzy algorithms
  • Loop control
  • Crop shear head and tail crop length control
  • Divide shear/divide cut length control and optimization
  • Process monitoring
  • Pre-configured trends for process diagnostics data logging 
  • Diagnostics and alarms
  • Delay logging

Sample of technical details and options: 
The basic system includes the following:

1. Quantum (Modicon) PLC including the IEC1131 programming software with extensive use of engineered function blocks and online documentation.

2.Windows NT workstation and dual screen displays for setup, control, monitoring and maintenance. The system is designed to control mill stands via any of the popular networks or through hardwired I/Os, (including Profibus(R), Modbus Plus(R), Devicenet(R), Interbus-S(R)).

The Mill Control System will typically interface to the mill drives through a high-speed network. 

When installed in an older mill, The Mill Control System can be interfaced to analog drives.

Options:

  • Pulpits and operator consoles
  • Control of auxiliary systems
  • Loop scanners and HMDs
  • System installation
  • Seamless transfer from existing system
  • Mill Operating System (MRP software)

SESA Training Mill Simulator

Practice rolling theory, mill setup and hands-on mill control
A real-time mill simulator helps train new operators and upgrade the skills of your current operators in understanding the basic principles of mill setup and controls. It provides a generic rolling operating environment through real HMIs with a control console and tests their operating skills to running a cobble-free mill. Through learning and comprehensive testing, the operators will gain the knowledge required to achieve high production levels and minimize cobble rate.

Benefits

  • Fast process to get new operators trained
  • Saves money by teaching good rolling practice
  • Help assess operator performance and their understanding of rolling theory and practice
  • Transportable
  • Can be custom-configured

Features

Mill Setup
The operator is trained step-by-step on the principles of proper mill setup.

The setup environment is generic and the emphasis is on the process (not what the screens look like).

Rolling Scenarios
Dynamic rolling is simulated. The operator downloads the mill setup, starts the mill and initiates charging billets from the reheat furnace. The simulator displays motor speeds and currents as the billet threads through the mill. The operator applies cascade speed trims to any of the stands and observes the changes to motor loads due to push-pull interstand forces. He is forced to react to events as if encountered in the normal operation of a mill.

Online Help
Help/teach feature assists the operator with basic theory of rolling and how it is applied in practice. Key topics covered are: mill setup, starting the mill, understanding interstand push-pull forces, understanding impact drop compensation, pass reduction and relationship to speed, understanding drives.

Operator Interface
The HMI screens provide a generic environment for basic understanding of rolling, suitable for training operators independent of their plant control system. Simulator and HMI screens can be adopted to represent the user mill configuration.

Rolling Theory
A comprehensive course includes basic rolling theory and hands-on rolling of shapes on SESA lab rolling mill to complement the mill control simulator sessions.

SYSTEM CONFIGURATION

Simulating PC
Running real-time models of mechanical and electrical equipment and metallurgical models of bar sections.

Mill Control System
A PLC controller board residing in the PC chassis running a real Mill Control System.

HMI
Operator interface screens (2) displaying setup, control and monitoring functions. A separate screen is dedicated to online help and rolling theory training 

Control console
A flat membrane keyboard, designed to provide the feel of a real operator console, complete with raise and lower push buttons for each stand and additional critical control action push buttons.

Furnace Control System
PLC-based arc furnace regulation and control system  with a superimposed powerful HMI station provides an easy to upgrade, yet sophisticated approach to EAF optimization. The overall system is based on the integration of various functional components which can be applied individually to a partial upgrade situation or supplied as a complete system for a new operating environment.

System components:

  • Electrode regulation
  • Furnace motion controls  
  • Harmonic analysis
  • Process and production monitoring
  • Engineering, production and performance reports

Expected benefits:

  • Lower energy consumption (KWHR/TON)
  • Faster melting cycle
  • Reduced electrode consumption (including less breakage)
  • Reduced refractory consumption
  • Enhanced operator's understanding of process performance parameters through performance indicators