Mubea, Germany, recently completed commissioning of a new Danieli flexible rolling mill for tailor rolled blanks (TRB). The mill was commissioned six weeks ahead of schedule.

The three partners — Mubea, Danieli Fröhling and Danieli Automation — credited close partnership during installation and commissioning as key to achieving the shortened time schedule.

The mill features a heavy duty design that provides a proven sturdiness during conventional as well as flexible rolling. The installation also includes a Danieli Automation HiPAC automation control system that provides speed and tension control; AGC including mass flow gauge control; hydraulic roll bending control; HGC force and position control; and roll eccentricity control. The automation system also provides threading sequences and operation modes; mill master speed control and automatic slowdown; and coiler tension and speed control.

The mill’s process control system, with a modular architecture, is based on a client-server configuration and simplifies operations and maintenance, thereby ensuring any future implementation. An Oracle database supports the practice database; coil order and result database; material database; event log and user security access rights; and process data log. The process control system also controls mill setup; the quality control system; material tracking and reports; rolling practice; mathematical model correction; and roll and equipment data.

The following mathematical models are implemented: force prediction; torque prediction; roll stack deflection (shape and profile); and pass-to-pass model adaptation. The plant communication network utilizes a 100 Mb/s Fast Ethernet, with Profibus field bus.

A Danieli Automation maintenance suite provides the mill with a set of powerful diagnostic tools to allow maintenance staff to monitor mill status and reduce MTTR. The assistance and maintenance suite includes an FDA Fast Data Analyzer, which acquires information on the process at high speed (less than 5 ms) directly from the local network in client-server mode; an EWS Engineering Workstation with software development tools for all process applications; and a laptop programming unit for accessing the Level 1 control systems.

Danieli Automation’s scope of supply includes main inverter switchboards, common DC bus for stands, reversing coilers and, bridle rolls; auxiliary inverter switchboards and MCC; starters for fixed speed motors; and main and auxiliary AC motors.