The advantages of a family of variable speed drives that meets the varying requirements of an entire steel production process can range from easier maintenance and fewer spare parts to single supplier interaction for improved support, reduced training needs and standardised/interchangeable equipment across the plant floor.
If the correct individual drives are available in and selected from such a product family, further benefits like faster, more flexible production and decreased downtime can be achieved.
Accordingly, several cut-to-length steel production lines in South Africa have recently moved from traditional set-ups to a single drive system solution for entire steel production processes. The modular, scalable system fulfils all the needs of a high-production cut-to-length line. Pre-programmed controls and operator control units, as well as intelligent drives with a wide range of rotary and linear motors ensure maximum productivity and product quality. The system satisfies synchronisation and positioning tasks in sheet metal, plastic, paper or wood processing applications whether the format is round, flat or contoured.
Matched and pre-configured system components represent the main design feature for quicker and easier installation than traditionally achieved, while standard machine operator controls mean operators are always at home with equipment throughout the plant. Training requirements are further eased as a result of menu-driven operation across the range, and a reduced number of peripheral components.
All control drive functions for typical roll feed applications rated up to 24 kW are covered by the complete automation system with intelligent single-axis control, including operator control and visualisation units, as well as digital drives, in which neither the NC control program nor the visualisation involves any programming. Operators simply activate the desired functions, input production data and start production - a commissioning process that is believed to be setting new standards in South Africa.
Typical requirements of roll feed applications are incorporated as complete functions, such as cam switch group or press encoder management. This reduces overall installation costs by doing away with external peripherals to take care of these functions. Built-in feed optimisation relates to the respective number of strokes, reducing energy consumption and wear.
This type of complete solution allows for the online fine adjustment of the feed length during current production. Start-point optimisation can further eliminate delays in auxiliary systems by allowing the maximum number of strokes. Up to 999 repetitions per single part length are possible with the optimum tool and speed selection. Comprehensive diagnostics provide continuous information about the status of inputs and outputs, actual and set point positions, as well as drive warning signals. Remote diagnostics can be provided via an external Internet adapter.
The completely assembled Optifeed drive system solution consists of an ELC high-performance, single-axis control in compact plug-in card format, and the Ecodrive digital drive system. The space-saving control is integrated in the digital drive, providing economical axis positioning. Available from Tectra Automation, this Rexroth Bosch solution incorporates servo drives with up to 64 positioning blocks, each with its own speed acceleration and rate-of-change limits, which can be stored in the control unit.
Analog, parallel, Profibus and DeviceNet interfaces are all accommodated.
A few local steel producers have also chosen to adapt the solution for use on flying cut-off lines, where product is continuously flowing through a welding process and cannot be interrupted. This requires the inclusion of a flying shearer that moves at the same speed as the steel material, cuts at preset lengths, and returns to its original position for the next cycle. Intelligent control and digital drive technology ensure high-precision production and maximum productivity.
Flexibility, reliability and reduced operator training - the advantages of a single-supplier solution that completely covers the entire drive and control requirements of a steel production line look to be changing the way in which project managers approaching the design of production processes. Traditional plant configurations with different pieces of equipment from various suppliers are likely to be phased out, as they are not able to deliver the same high speed of production and quality standards now provided by complete solutions.
For more information contact Georg Venter, Tectra Automation, +27 (0) 11 971 9400, [email protected], www.tectra.co.za
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