Long Rolling Rod Mill Laying Head Controller

The Long Rolling Rod Mill Laying Head Controller is a control system for wire rod mills. It assists the operator, maintenance engineer, production manager, quality control specialist, and plant manager in a wire rod mill. These professionals aim to achieve improved production efficiency, ensure high product quality, and minimize operational costs. The controller increases operational efficiency, improves product quality, and delivers significant cost savings. It accomplishes this through precise control over the laying head, control over pinch roll processes, and seamless integration into existing systems.

The Long Rolling Rod Mill Laying Head Controller plays a crucial role in managing the tail end and front end control of the wire rod. This system ensures that the wire rod is laid out correctly on the Stelmor conveyor and formed into coils efficiently. The process involves two main components: the laying head and intelligent pinch rol in front. This controller adjusts the speed and positioning of the wire rod as it exits the last rolling stand. For smaller, high-speed products, the system uses tail end step-down control to prevent the formation of oversized rings, which could disrupt the laying pattern. For larger, slower products, it employs tail end speed-up control to avoid undersized rings. The front end of the wire rod must be accurately positioned relative to the conveyor's direction to prevent snagging, which could lead to operational downtime. The controller continuously measures the rod's speed and makes real-time adjustments to ensure smooth operation. This involves correcting the speed as the rod exits the rolling stand, accommodating the high inertia of the laying head. The controller helps maintain optimal product quality and minimizes potential disruptions in the wire rod mill.

Benefits of the Long Rolling Rod Mill Laying Head Controller

• Improved product quality: by ensuring precise control over the tail and front ends of the wire rod, the controller maintains accurate laying patterns, preventing defects like oversized or undersized rings and ensuring high-quality output.
• Operational efficiency: the controller's ability to maintain consistent control over the laying head and tail end speeds helps streamline the production process, minimizing disruptions and ensuring smooth operation, which leads to higher throughput and productivity.
• Reduced maintenance needs: by preventing operational issues that can cause equipment wear, the controller decreases maintenance frequency and costs, extending the lifespan of mill components and promoting more sustainable operations.
• Reduced downtime: with its precise control capabilities, the controller minimizes the risk of operational issues such as snagging or misalignment, which can cause significant downtime. This reliability ensures that the mill can operate continuously without frequent interruptions.

Features of the Long Rolling Rod Mill Laying Head Controller

• Dynamic tail end control: the controller provides both step-down and speed-up capabilities, allowing for precise adjustments based on the product size and speed requirements. This dynamic control is crucial for maintaining the correct laying pattern and ensuring efficient coil formation.
• Real-time speed adjustment: the system can quickly measure and adjust the rod speed, even with large changes in the laying head. This feature is particularly beneficial for maintaining control at speeds up to 110 m/s, ensuring that the production process remains uninterrupted and efficient.
• Seamless integration: designed to be compatible with existing plant systems, the Long Rolling Rod Mill Laying Head Controller can be integrated as an independent software package. This compatibility extends to major automation platforms, providing flexibility and ease of implementation.
• Enhanced front end positioning: the controller ensures that the front end of the rod is positioned accurately relative to the Stelmor conveyor, preventing snagging and ensuring smooth transport. This precision is maintained within a +/-30 degree tolerance, even at high operational speeds.
• Advanced process tracking: the system tracks the rod from the last rolling stand through the laying head, accounting for variables such as billet temperature and cooling water effects. This comprehensive tracking ensures consistent control over the production process.