s continuously strives to improve the technology of the metals processing industry

8/8/2019 S Continuously Strives to Improve the Technology of the Metals Processing Industry

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S continuously strives to improve the technology of the metals processing industry. Pleasecontact us if we can answer any questions regarding our technology development and

capabilities. Read about our development of a Field Programmable Grid Array (FPGA) motioncontrol system.

y A New Architecture for Automatic Gauge Control Systems

y Automatic Gauge Control y Elongation Control

y Statistical Process Control

Automatic Gauge Control - AGC

I2S has designed, manufactured, installed and started up well over one hundred computerized

Automatic Gauge Control Systems based on the mass flow equation. In the words of our

customers, these systems are ³outstanding performers.´ I2S, LLC has installed AGC on one waymills, reversing mills, tandem mills, Two-Highs, ST 20 High Cluster Mills and combination

Four-High / Z-High Mills.

The I2S, LLC Computerized AGC System has two modes of operation:

1. Computerized adaptive feed forward control using the mill screwdown as means of

correction also referred to as a "Mass Flow".2. "After the fact" control using only the exit gauge

The Mass Flow Method of Gauge Control The basic adaptive feed forward system uses the

following inputs:

y E

ntry Thickness Gaugey Exit Thickness Gauge

y Entry Pulse Generator y Exit Pulse Generator

y Separating Forcey Mill Modulus

The basis for the mass flow gauge control is that the volume of metal that is entering the mill isequal to the volume of metal leaving it. The basic equation is: Lin x Tin x Win = Lout xTout x

Wout. The philosophy is to compute the thickness of the strip leaving the roll bite in the smallest practical increment of strip travel and issue proportional corrections to the mill screwdown. By

utilizing this robust mathematical model, thickness control is optimized even while runningslowly and during speed changes.

The exit thickness gauge is used as a master reference, and this gauge is read and averaged everytime the primary loop is read (Volume in = Volume out). If the primary loop is not maintaining

the exact desired thickness, it is adjusted slightly to bring the average output strip thicknessdeviation to zero. This cycle of events is repeated on a continuous basis and system adjustments

are made as necessary.



The ³After the Fact´ Method of Gauge Control The other mode of gauge control is the exit feedback method. This is called ³After the Fact´, onlegacy mills "GB-

100". This mode

uses only the exitgauge for makingcorrections to the

screwdown. Onetach, either driven

off the exit side of the mill, or the

mill tach(whichever is

available), is usedto initiate the

corrections. It is based on the

assumption thatthe thickness of

the metal in theroll gap is the

same as thethickness at the gauge. It reads the gauge over a short interval and averages these readings to get

a better idea of the thickness of the metal at the roll gap. If this averaged thickness is differentthan the desired thickness, the mill screwdown is issued a command to move a proportional

amount based on mill modulus and separating force.

This system is used on the loading passfrom the payoff, when entry side pulse

tach or strip thickness gauge cannot beused.

Back to Top Elongation Control

The I2S elongation control system

acquires elongation comparison signals by

means of two high resolution tachometers(entry & exit). A tach termination board

processes the signals into the tachinterface board contained in the industrial

IBM compatible computer.

I2S' elongation software then analyzes thetach signals. By comparing the measured

"length in" with the measured "lengthout" of the strip, the actual elongation is



calculated. If the specified elongation is not being achieved, the screwdown control board sendsmovement commands to the hydraulic screwdown system. Adjustments in the screwdown force

increase or decrease the elongation to match the specified elongation setpoint value entered byyour operator.

The I

2

S elongation control system continuously monitors the actual elongation to make sure youachieve your customers' specifications, consistently. For more information on applying our elongation technology to your company's particular production, please contact a representative in

our sales department.

Back to Top

Statistical Process Control - SPC

Why SPC? Prevention vs. Detection A traditional approach to manufacturing is to depend on production to make the product and on

quality control to inspect the final product and screen out items not meeting specifications. Inadministrative situations, work is often checked and rechecked in efforts to catch errors. This is

wasteful because it allows time and materials to be invested in products or services that are notalways useable. After-the-fact inspection is uneconomical; it is expensive and unreliable, and

wasteful production has already occurred. (*)

A prevention strategy sounds sensible -- even obvious -- to most people. It is easily captured insuch slogans as, ³Do it right the first time.´ However, this kind of cheerleading is not enough.

What is required is an understanding of the elements of a Statistical Process Control system. (*)

The I2S, LLC SPC data gathering system is largely based on the methods and interpretations asoutlined in the Ford Motor Company¶s publication listed in the footnote below.

(*) Taken from the Ford Motor Company¶s booklet number 80-01-251 ³Continuing Process

Control and Process Capability Improvement´ September 1985.

Overview of the SPC/QC SystemWe sample the gauge deviations from the exit gauge and use them to generate range and average

charts. Standard deviations and Cpk values are also calculated.

While the mill is running we also display range and average charts on the screen, a kind of ´SPCon the fly.´ These charts are constantly being updated while the strip is being rolled and provides instant feedback to the operator on how the gauge quality is being maintained. There

are also screens on the computer that enable the setting of specification limits, full scale rangingfor the charts and other setup information.

At I2S, LLC we do not stop our quality reporting with these SPC charts, we also provide other

optional methods of inspecting gauge control quality.



It is a crucial part of business today that for every process control system there is a flexible, easy

to use, quality control system that can be used to monitor performance. With the I2S, LLCautomatic gauge control coupled with the SPC/QC reporting package, control and verification go

hand in hand.

Products:

I2S Designs, Manufactures, Revamps, Installs, Commissions & Services Cold Rolling Millsand Ancilliary Equipment.

Mill Ty

y y y y y y y y

Non-CoSystem

y y

Two High Mills (2HI) for specialty applications

I2S, LLC can supply 2 High mills for specialty applications.

These mills are occasionally a better solution than 4 High mills for light reductionand camber control for in-line use such as roll forming and stamping operations.

Heavy reduction of plate material is another area where 2 High mills, with their

large roll bite, are often used. Lastly, we provide many 2 High mills for skin pass /surface conditioning applications. Please refer to our section on Temper / Skin Pass

Mills for more information.



Four High Mills (4HI) for all applications

Four high mills are probably the most common typeof mill

and are used throughout the ferrous and non-ferrous

metal industries. Four highs can be used for heavygauge "breakdown" rolling, for relatively thin gauge

finish rolling and for temper / skin pass rolling.

Four highs can be supplied for one way operation, for

reversing operation or in multiples for tandemoperation

At I2S we have designed and manufactured 4 highs

ranging in size from 2" & 5.25" x 8" to 21" & 49" x108", speeds from 10 FPM to 3,300 FPM and

separating forces from 50,000 lbs to 7,000,000 lbs.

Bonding Mills for cladding and inlay applications

I2S has designed and supplied bonding mills for cladding an

assortment of ferrous and non-ferrous metals. Clad materialsrange from multiple "full strip width" layers such as used for

coin stock to multiple inlayed strips used in the precisionelectronics industry.

I2S bonding mill lines include multiple uncoilers, strip clean

equipment, take-up reels, etc.

Back to Top

20 Hi Cluster Mills (ZR Mill)

20HI or "ZR" Mills (20 High Cluster Mills) to meet every requirement!



I2S has developed a line of very successful 20 Hi Cluster- monoblock

20HI Mills for accurate thin gauge production. These mills are also the best choice for heavy reduction of harder

materials such as stainless steel due to the rigidhousing design and work roll support within

the cluster.

Aside from I2S' own design in various sizes

and widths, I2S also offers licensed versions of

the T. Sendzimir, Inc. ZR Mill. Please take a

moment to review some of the features thatcontribute to this superior design as well as a few featured projects

which are available for download in PDF format from the link on this page.

Tandem Mills

New and Modernized Multi-stand Mills

I2S has designed and supplied new Tandem Mills and equipment modernizations in many configurat

Those Mills feature the I2S patented hydraulic screwdown system, AGC, drive systems, inter-stand

and mechanical equipment innovations.

Temper Mills

Temper Mills - Stand Alone or In-Line Applications.

Temper mills are an integral part of the processing of metal.

Recent trends have caused an increase in the use of Temper Mills as part of processing lines. I2S has provided Temper/Skin

Pass Mills for tension leveling lines, galvanizing lines, cut-to-length lines and stamping/roll form lines.

Those Mills are designed to produce coils with superior flatnessand surface quality, reducing coil spring-back for downstreamoperations and therefore increasing the value of the material to

the end user.



Tube and Pipe Mills

I2S provides patented in-line gauge and camber controls for today's high speed, high precision, weldforming, and stamping lines.

Important features related to the I2S Tube and Pipe Mills:

In-Line, real time, adjustment of incoming raw materials to /- 0.0005" of desired tolerance (within th

capacities of a given mill). Based on a maximum incoming strip thickness variation rate of 0.0005" plength.

Wire Flattening and Shaping Mills

Let I2S be your source for wire flattening and shaping equipment. Flattening and shaping mills can b

designed for ferrous or non-ferrous products. I2S has built wire shaping lines that have incorporated

mill stands with speeds up to 1000 FPM. Higher speeds are available.

Non-Contact Gauging Systems



Gamma Gauges

I2S now offers the first "Mill Duty" Gamma Gauge designed and built by a fully integrated mill builder

the harsh mill environment.

The new system consists of a resistive industrial touc

and a Pentium computer which can be used as a StanSystem. It can also be fully integrated into a comple

utilizing AGC, SPC, and Programmable Logic (PLCoptional Strip Profile feature automatically traverses

the width of the strip, detecting each edge, and graphreproduces the profile of the strip thickness on the co

I2S has researched and utilized the most advanced ha

to remove drift and noise. Our preamplifier electroni

designed from the ground up to offer superior signalwithstanding the significant shock hazards so commomills. The computer uses many of the same boards w

AGC and touchscreen computers thus reducing spareour customers.

I2S has also improved all of the electronic components to take advantage of the latest advances

in opto signal processing. The gauge interface boards are all printed circuit type and designed

with quick release terminal strips for ease of installation and troubleshooting.

Gauge controls, gauge set up parameters, and calibration are all accessed through the

touchscreen and can be saved to disk. All system readouts can be displayed in English units or Metric.

All controls are accessed through the main menu. Our new Alloy Screen allows the operator toassociate the material composition number to the more familiar name that is used for the

material. Once entered, the alloy is then selected by its desired name and the internalinformation is automatically entered into the computer system. Set gauge, source on/off,

standardization, as well as an electronic strip chart display simplifies calibration and operationof the gauge. The I2S, LLC non-contact gamma gauge is the finest available.

Our gauge system has never been easier to operate or set up. Complete system knowledge including op

calibration, troubleshooting, and maintenance can be attained through a minimal amount of instruction

The I2S gamma gauge has been designed for the rugged industrial mill environment and complies with

Nuclear Regulatory Commission and international standards for gauge safety.

At I2S, LLC, we are continuously researching and developing the latest in technology to keep you at thtoday¶s high-tech metals processing industry.



Back to T

X-Ray Gauges

Do you need to measure something as thin as newsprint? Something as thick as an inch of steel? Do yo

gauge to be non contact? Fast? Reliable? Able to hold tolerance to an accuracy of 0.1%?

No problem. The I2S X-Ray Gauging System does all this, and more. We are offering a completely new

design with many advantages:

y Ion Chamber has excellent stability and long life Rugged, simpleconstruction.

y Significantly improved temperature stability over photomultiplier systems.

y Bullet-proof design.y New high frequency X-Ray generator offers quick response, low

ripple and high stabilityy Fast alloy compensation ability

y Digital, Pentium based, touch screen controly Embedded real-time signal processing hardware integrated with

Windows 2000/XPy Supervisory control Remote I/O control of generator subsystem

resulting in reduced wiringy Constructed from commercial off-the-shelf (COTS) components



y Further enhances the I2S SinResponsibility!

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s continuously strives to improve the technology of the metals processing industry

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