Long Rolling Bar Mill Expert

The Long Rolling Bar Mill Expert is a software solution for optimizing bar mill operations that assists plant managers, production supervisors, and quality control specialists in a bar mill. It helps achieve consistent production flow by increasing process stability and enhancing operational efficiency. Additionally, it reduces downtime and operational inefficiencies through optimizing operations in the rolling mill area, enhancing cooling bed processes, and supporting high-speed processing.

The Long Rolling Bar Mill Expert is a comprehensive system designed to optimize operations at both the cooling outlet and the high-speed outlet (SLIT), ensuring precise and efficient bar mill performance. Its advanced components work in unison to enhance productivity and product quality across the entire rolling process. Key features include the Minimum Tension Controller, which reduces interstand tension for smoother rolling, and the Impact Controller, which compensates for speed drops in high-speed finishing mill stands. Accurate shear operations are ensured by the Shear Master, while the Long Rolling Bar Mill Cut Length Controller optimizes billet lengths and manages shear cuts for maximum efficiency.

At the cooling outlet, the Divide Shear system cuts bars into cooling bed lengths based on material speed and preselected cut lengths. This process is supported by the Cut Length Strategy and Optimization, enabling flexible and precise length adjustments. The Cooling Bed Run-In Roller Table and Brake Slide ensure precise material positioning, while Moving Rakes and Aligning Rollers dynamically control product flow according to product size and cooling schedules, ensuring proper charge separation and clearing.

The high-speed outlet SLIT manages operations from the rolling mill exit to the Rotary Entry System (RES). It features the Enhanced Temperature Control System, which ensures uniform tensile and microstructural properties by maintaining precise temperature profiles. This system increases yield by quickly achieving the desired laying head temperature. Dividing, Crop & Cobble Rotary Shears adapt to mill speed for precise cuts, while the Power Slitter regulates speed and adjusts bite angles. The Cut Length Strategy and Optimization module evaluates remaining material length in the continuous mill, redistributing the last bars to fit normal dividing lengths, down to a minimum, with the option for manual presets.

Braking Pinch Rolls stabilize the rolling process, controlling product slowdown as it enters rotary drums and initiating front-end tracking after upstream dividing shear cuts. The RES, with its rotating drums, slows down the bar and deposits it onto a fixed position on the cooling bed sliding notch. This system precisely controls braking time and coordinates the movements of the RES to ensure seamless handling and placement.

Benefits of Long Rolling Bar Mill Expert

• Quality assurance: by maintaining precise control over the rolling and cooling processes, the Long Rolling Bar Mill Expert ensures that the final products meet the highest quality standards.
• Operational efficiency: the system is designed to optimize the rolling process, reducing downtime and increasing throughput. This is achieved through efficient material handling systems, which streamline the flow of materials through the mill.
• Enhanced precision and control: the Long Rolling Bar Mill Expert provides precise control over the rolling process. This ensures that each bar is cut to exact specifications, minimizing waste and ensuring uniformity across products.
• Reduced maintenance needs: the robust design of the system minimizes the need for frequent maintenance, thereby extending the lifespan of the equipment.
• Cost savings: with precise control over production processes and maintenance management, customers can reduce operational costs, minimize downtime, and extend equipment life, resulting in significant cost savings.