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BMM Ispat Ltd, India Siemens VAI Metals Technologies


Merchant Bar Mill GmbH&Co
E&A India
I MT
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The unauthorized use of this documentation or use
contrary to its intended purpose is not permitted
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BMM ISPAT LTD.


MERCHANT BAR MILL

TECHNOLOGICAL BLOCK DIAGRAM FUNCTION


&
HELP FILE

SLI DOCUMENT NO. - C.SP70.LB.91.50 -D/DOK001


BMM DOCUMENT NO. BMM-P06-02-M001-05-20-000-EA-001
CONSULTANT NAME R.SINGH & ASSOCIATES (P) LTD
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00 Revision 23 Apr 14 MMB ARM


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Rev. Modification contents Date Made by Checked by


Mandatory Contract No
C.SP70 Project BMM ISPAT LTD. Date Name
Made by 20-Mar-2014 MMB
LB Plant MERCHANT BAR MILL Checked by 20-Mar-2014 Amar Mulatkar
Approved by 20-Mar-2014 VB
91 Area CM Eng. BD Secl. CU

50 Equipment Lang. EN Size Sheet 1 No. Sheets 115


Material
0 SubGroup Mass Unit
Scale1 Scale2
D SupplyGrp Electric SAP Document No.
Special Partner
Partno Special Partner No.
Sub
DOK DocType Function Block Help File Sub No.
Corr. Doc.
001 CountNo Customer No.
Doc Title Technological Block Diagram Function & Help File Substitute for
Replaced by

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I MT
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Confidentiality
This document contains valuable trade secrets and confidential information of Siemens VAI and the content of this document is and
shall remain our intellectual property right. You shall keep this document and all its content strictly confidential, not disclose it or any
part thereof to any third party without our prior written consent and not use any information, specification or data contained in this
document for other purposes than for the evaluation of our document.
No part of this document is allowed to be adapted, copied, reproduced, duplicated, translated into another language, distributed or
processed (print, photocopy, microfilm or any other process), neither by the use of electronic systems nor otherwise without the prior
and shall be prosecuted.

written permission of Siemens VAI.


You shall limit access to our document and to any part thereof to those of your employees reasonably required being aware thereof and
you shall ensure their strict adherence to the provisions of confidentiality and restriction of use as expressed above.
Any violation of the above provisions will be brought before the competent court in accordance with the applicable law.

Contact Information:
Amar Mulatkar
Siemens Ltd.
Industry Sector
Metal Technologies
IN I-MT OP E&A
Plot No. D-41/1, TTC Industrial Area
M.I.D.C. Turbhe, Opp. MTNL Exchange
Navi Mumbai - 400 705, India
Tel : +91 22 67615100 (Ext: 5336)
Fax : +91 22 25820008
Mobile: +91 9820924052
Mail to : amar.mulatkar@siemens.com

Revision History

Rev Date/Made by Description Date/Checked by

00 23th Apr 14 Issue ( Preliminary ) ARM


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List of Contents
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5.2 BASIC AUTOMATION OVERALL-FUNCTIONS 4


5.2.1 OVERALL FUNCTIONS MILL ENTRY AREA 6
5.2.2 MILL AREA 7
5.2.2.1 MILL OPERATION FUNTIONS 7
and shall be prosecuted.

5.2.2.2 MILL TECHNOLOGICAL FUNCTIONS 10


5.2.2.2 MILL STOP AND COBBLE CONDITIONS 15
5.2.3 MEDIA SYSTEMS 24
5.2.4 TRACKING 25
5.2.5 PROGRAM STRUCTURE 27
5.2.5.1 CTR 27
5.2.5.2 SHE: TECHNOLOGICAL FUNCTIONS 77
5.2.6 COL 87
5.2.6.1 BAR EXIT SECTION : 87
5.2.6.2 DIVIDING SHEAR 87
5.2.6.3 CUT LENGTH STRATEGY 88
5.2.6.4 COOLING BED LENGTH CUTTING 88
5.2.6.5 COOLING BED INLET ROLLER TABLE AND MAGNETIC BRAKES 88
5.2.6.6 MOVING RAKES AND ALIGNING ROLLERS 88
5.2.6.7 COOLING BED EXIT 88
5.2.6.8 COLD SHEAR CUT 88
5.2.6.9 MECHANICAL BAR COUNTER 89
5.2.8 MIL / MED 105
5.2.9 EMERGENCY SYSTEM : 114
5.2.9.1 GENERAL 114
5.2.9.2 EMERGENCY STOP ON OPERATING STATIONS 114
5.2.9.3 EMERGENCY STOP PANEL 114
5.2.9.4 EMERGENCY STOP MATRIX 115
5.2.9.5 DRIVE'S RESPONSE TO EMERGENCY 115

TOTAL PAGES 115


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5.2 Basic Automation Overall-Functions

Automation System
and shall be prosecuted.

Introduction

Introduction Level 1 Basic Automation System (BAS)


The Basic Automation System is responsible for

Mill set-up

Technological controls such as

- MTC: Minimum Tension Control


- LOC: Digital Loop Control
- Cascade Control
- Cut Length Control
- Material tracking
- Cut length Strategy

Superimposed high-speed sequence control, etc.


The area controlled by the Siemens PLC systems includes:

MILL AREA

- Furnace charging, discharging


- Mill Entry RT, Divide shear for Line A , Line B and Line C
- 16 Stand Mill incl. 3 up Loopers and 2 shears

Cool AREA
- Divide Shear
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- Pinch Roll Before Divide Shear


- Inclined Roller

Cooling Bed Area


- Cooling BED
- Magnetic Chain Transfer System
- Rake Control.

CPU Arrangement - Basic Automation System (BAS)


The following page displays the design of the automation system
The System consists of the following CPUs with the following functions:

CTR: Overall Control of the mill area

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Reference value coordinator that provides speed reference values, manages


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operating modes, executes cascade functions and handles the pass


schedule.

Sequencer tracks head and tail of the billet (rolling stock) in the mill to initiate
the necessary actions depending on their positions in the mill.
and shall be prosecuted.

Minimum Tension Control up to stand 12

Loop Control for Uplooper from Stand 13

Provide actual and reference values for displays on HMI

Data interchange and control of adjacent CPUs

Control of DSM (Drive switching and monitoring) of the drives

Fast control of the shear cutting (head, tail, sample and cobble cut, etc).

COL: Control of the Line COL Area, Cooling Bed (mill area) and Bar Area

Control of the Divide Shear , pinch roll , Inclined Roller.

Control of the Water Box

Control of the Cooling Bed, Magnetic tray transfer.

MILL (MIL): Control of the auxiliary equipment & auxiliary functions in the mill area

This system controls the cooling water, hydraulics, oil lubrication and grease
systems in the mill.
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5.2.1 Overall Functions Mill Entry Area


When the billets in the furnace have the correct temperature and the mill is ready for rolling the billets can
be discharged from the furnace. Billet enable discharging from the furnace is done on command of the mill
automation system or directly from the main pulpit.
The billet first runs through the descaler to get rid of the scale. This is done by spraying water with high
and shall be prosecuted.

pressure on to the billet.


The billet will be transported by two rollertable sections towards the first stand.
The billet temperature has to be monitored while it comes out of the furnace due to certain temperature
limits that have to be met. It the temperature is out of limit the billet should not get into stand 1 and has to be
taken off of the RT in responsibility of the operator.
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5.2.2 Mill Area

5.2.2.1 Mill Operation Funtions


and shall be prosecuted.

For a new shift or after a roll change or after some maintenance jobs the sequence to start the mill should
always be the following or at least part of the following:

1. Take over Pass Schedule

2. Check pass schedule data for plausibility, possibly modify the pass schedule data

3. Check the dummy stand selection and varify with the hardware

4. Switch all areas to Automatic mode and check feedbacks

5. Start the mill and wait until all drives are up at reference speed

6. Start ghost rolling (simulation) to varify the proper operation of loop scanners and HMDs

7. Stop ghost rolling (simulation)

8. For desired speed corrections the cascade function is used

9. Call billet from the furnace to start production

This system is designed in a way that production is possible only in automatic mode.

5.2.2.1.1 Pass Schedule Takeover and Plausability Check


The pass schedule contains, among other data, the speed reference values for the main drives. Upon
actuation of the function key "TAKE OVER ROLL SCHEDULE" (HMI) the material speeds are converted into
motor speeds. REF verifies the calculated and entered speeds with preset limit values (default: 95 %). In
addition a consistency check is performed (rising material velocity etc). If errors are detected (limit
violations, data inconsistency, etc.), a message will be issued with the corresponding stand number. The
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incorrect data record won't be used. If no error is detected, the new pass schedule data is transferred to the
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subordinated control systems.

5.2.2.1.2 Inactive Stands (Dummy Stand) Handling


Depending on the actual pass schedule (the actual mill configuration) some stands may be taken out to roll
certain sizes of material. These stands are switched off (not selected stands/inactive stands) and they are
designated as dummy stands. For a dummy stand (n) the reference value of the preceding stand (n-1) is
used.
However, the speed reference value is not output to the drive.

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5.2.2.1.3 Switch All Areas to Automatic and Start the Mill


To be able to start the mill (for production) the following systems have to be in operation or ready to run:

Fluid Systems
and shall be prosecuted.

Air System

Main and Auxiliary Drives (at least in the respective areas)

Shears synchronized

Snap shears open

No E-Stop and no Normal Stop active (in the respective areas)


With the HMI system the operator can switch on all Drives and all Systems. The HMI screens also indicate
the status of the different systems by color-coding, thus providing the operator with an overview of the mill
status at all times.
To start the mill for production, the operator selects AUTOMATIC operation for all areas. All areas (drives
and devices) will acknowledge a ready for operation signal if all conditions for automatic rolling are fulfilled.
Now the operator can start the mill with the mill start button.
When the mill start button has been operated, the mill will ramp up on a common ramp. After all drives have
reached their setpoints and no error did occur the mill is ready for rolling. Now the operator can start ghost
rolling to simulate rolling or he can give the command for a single billet or for continuous billet pushed out
from the furnace.

5.2.2.1.4 Ghost Rolling


Ghost rolling requires automatic mode for the mill. Under automatic ghost rolling can be selected. This mode
simulates all HMDs and loop scanners with a virtual rolling billet so it will check the functionality of these
devices. The mode selection is made on the HMI.
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5.2.2.1.5 Cascade Control and Stand Individual Adjustment


Cascade control is provided to enable the operator to react to conditions in the mill that require speed
corrections or change of speed relations or speed up the entire mill by selecting the leading stand. Cascade
control is applied to all drives that are in contact with the actual rolled material.
After selecting the desired stand with a stand identification key, the "Follow-up" joystick can adjust the stand
and shall be prosecuted.

speed (increase slow /fast or decrease slow/fast) with the respective acceleration rates. Adjustments will
take place upstream of the selected stand towards the furnace, where as the speed ratio between two
stands remains unchanged during the follow-up adjustment except for the selected stand and the next stand
downstream.
The cascade adjustment is possible only in the automatic operating mode.
The stand individual adjustment enables the speed correction of individual stands. The speed of the
selected stand is adjusted, without influencing the speeds of the other stands.

5.2.2.1.6 Call for Billets Interface to Entry


The furnace control system loads a billet on the furnace exit part and submits a "Billet ready for extraction"
signal. Then a "Send billet" request according to the mill sequencing is send back to start extracting billets
from the furnace.

In case of any error or missing ready signal, the automation will prevent the next billet to
be loaded into the mill.
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5.2.2.2 Mill Technological Functions

5.2.2.2.1CTR Control: Minimum Tension Control (MTC)


and shall be prosecuted.

Minimum Tension Control is a digital open loop control system that calculates additional speed reference
values depending on specific tension in the material obtained from the motor current.
MTC is applied between all stands.
The minimum tension control has the following functions.

Measuring of drive currents and according specific tension

Adapting speed relation factor Vn for all drives

Calculation of additional speed reference values to achieve optimal tension

Pass schedule update for speed regulation factors


The following are preconditions for proper operation of the MTC:

Extremely low roll eccentricity

Temperature profile and dimensions of each billet should be constant throughout complete
length

Intervals between billets; more than 3 seconds

A minimum rolling torque of 20 % to 30 % from the rated torque for each stand

Travel time of the billet head is 0.7 seconds between two stands to recalculate new
reference values for the next billet.

Travel time 1.2 seconds for additional speed reference values on the same billet.
The specific material tension in bar mills depends on the speed ratio between stands. The factor KE
describes the relationship between speed changes (in %) and resulting specific tension changes. The factor
KE is a rolling specific factor and is based on rolling experience.
The MTC calculates during billet threading, the specific tension 1 and 2 before and after the billet heads
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into the next stand. The difference between those two tension values, minus tension set point is used to
calculate using KE an additional speed factor fnz [%]. The tension reference value is used to ensure that there
is a positive tension for all circumstances and disturbances.
The specific tension 1/2 is calculated from the stand drive armature current, considering actual speed, motor
power, motor base speed, armature base current and stand figures (gear ratio, roll diameter, cross section).

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The specific tensions 1 and 2 differ in the time when they are obtained. For 1 the armature current is
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measured when the billet is in the stand and has not reached the next stand, 2 is the tension when the billet
has reached the next stand. Delay times caused by load step changes and controller adapting needs to be
considered. The billet head tracking and pass schedule data are used by MTC to determine when to
measure the current. Operator interventions (speed changes) will stop the current measurement.
The armature current signal is filtered in the drive and on the analog input card to eliminate ascents and
power supply disturbances.
and shall be prosecuted.

For large values ( 1- 2) the adapting factor KE will be lowered to 80 of the calculated KE; for small values
( 1- 2) KE will be reduced to smooth controller actions during rolling when all conditions have been
established. The factor KE and the limits to switch KE need to be adjusted during commissioning.
The additional speed references created in MTC are ramped in MTC to avoid output steps to the drives.
The MTC generally affects all other stands in MTC accessing direction. That means the additional speed
reference for one drive contains the stand related MTC value and the MTC values of the previous stands in
MTC access direction as well.
The speed reference value for one stand is calculated out of the previous stand speed, using speed relation
factor Vn and the MTC correction factor fnz.

Vn = n * (Drive n) / n * (Drive n+1)


The speed reference value of the previous stand in MTC accessing direction contains also MTC values of
the previous stand.
The additional speed reference value is limited to adjustable max. and min. values. Ramp output functions
in MTC are stopped when a limit is reached. Additionally the ramp functions are stopped when the absolute
speed reference of the Speed Master reaches a limit value. Error messages are created to the MMI system.
After thread in when MTC has calculated the new speed ratio factors between stands for minimal tension
this value is transmitted back to the pass schedule management system and can be used for off line
calculations to optimize KE and Vn.
Three operation modes can be defined for each individual MTC. These operation modes are determined by
rolling recipes, billet head speed and inter-stand distances.

Mode 1:
If the billet head running time between stands allows two current measurements, then the additional speed
reference can be added to the stand speed for the same billet.

Mode 2:
If the billet head running time between stands allows only one current measurement, then the correction
values are stored in the pass schedule and used for the next billet. In this case MTC has adaptive behavior
over several billets.
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Mode 3:
If the billet head running time between stands is too small to take current measurements, MTC is switched
off. The time necessary for current measurement depends on the time for the current to calm down after
thread in.
MTC operation modes will be calculated in the PLC after a pass schedule is transmitted to the Speed
Master.

DUMMY MODE
If the pass schedule contains a dummy drive (stand not used for rolling), a speed reference value for this
stand will be maintained in the Speed Master CPU. This ensures that the function chain for MTC is not
broken and speed changes for stands behind the dummy stand also affect speed references for stands
before the dummy stand. MTC for dummy stands is switched off and the speed output to the drive is set to
zero.
MTC dummy mode is also selected when MTC is turned off for individual stands by operator intervention.

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5.2.2.2.2 CTR Controls: Loop Control (LOC)


The controller is active from the moment the head of the material enters the stand downstream of the loop
until the tail of the material is about to leave the stand upstream of the loop. Speed corrections, if any, are
automatically considered for the preceding stand and auxiliary drives, but only for those which are in direct
contact with the material.
and shall be prosecuted.

To prevent a whiplash, the loop height is reduced to a low loop before the tail leaves the stand. This speed
correction is done only for the stand preceding the loop. Loop height and any error are indicated in the main
pulpit.
MTC and LOC act upstream, opposite to the rolling direction. Thus the finishing speed towards the Loop
Cooling Conveyor is kept constant. The interaction of minimum tension and loop control ensures uniform
material structure and surface finish with minimum dimensional variations.
The actual loop heights will be within the range of 150 350 mm.
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5.2.2.2.3 CTR Controls: Speed Reference Calculation and Coordination (REF)


The speed reference value coordinator processes the drive speed references which are transmitted from the
pass schedule management system (WinCC). It also handles interlocks to subordinated drive control
systems. In addition, REF provides data logging for actual values from the stand drives and internal actual
values.
and shall be prosecuted.

The tasks of the REF are:

Speed reference control for drive systems:

- Reference value calculation and coordination


- Motor speed supervision
- Cascade control
- Operating modes
- Speed modes
- Self learning

Speed and load data logging for:

- Mill stands
- Shears
- Pinch rolls
- Roller Tables

5.2.2.2.4 CTR Controls: SEQUENCER (SEQ)


The head and the tail of each billet in the rolling mill is tracked to initiate shear cuts, persuader rolls, etc. in a
timely fashion to ensure a smooth operation and to avoid the occurrence of cobbles in the mill. Depending
on the position of the head/tail of each billet, the necessary enabling and inhibit signals are provided for:

Setpoint setting

Start of shears (cropping or chopping function)

Sequence control for loopers, MTC


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Automatic cobble detection


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For this purpose material is detected by means of:

Hot Metal Detectors

Digital Loop scanners

Stand Loaded Signals.


Using this information the control system knows the exact position of head and tail of the billet(s) in the mill
at any time.

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5.2.2.2.5 SHEAR CONTROL


The speed reference value of each shear depends on the speed reference value of the preceding stand and
a lead speed factor that can be adjusted via the WinCC system.
and shall be prosecuted.

Start / Stop Shears


The start signal for the shear drives are calculated and initiated on the basis of the actual material speed
and the pre-selected crop length. The following steps take place:

Shear speed calculation according to the actual lead speed (3 different lead speeds: Normal
cutting, Front and Tail cutting)

Material detection ahead of the shear

Start signal to the shear is given based on the actual position of the material in the mill

Cut

Re-positioning of the blade for the next cut cycle


The shear blade is returned to its starting position by automatic position control as part of the shear control
unit.

Shear synchronization
Before the shear is ready for automation it has to be synchronized. This is necessary for the shear to find its
proper position. If the shear is synchronized it will forward this information to the automation system.
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5.2.2.3 Mill Stop and Cobble conditions


The following Mill Stop and Cobble conditions are implemented in the automation:

1. Normal Stop: Ramp down after material clear


and shall be prosecuted.

2. E-Stop

3. Cobble Stop and Cobble Cut

4. Prevent next billet


If a mill condition causes one of these fault stops the corresponding drives should act according to the stop
and cobble matrix following hereafter.

1. Normal Stop
Normal Stop is initiated by Automatic off on Mill Stop.
Drives are stopped by ramp down function.

2. E-Stop
Please refer to Emergency function given in E-stop matrix as mentioned in Morgan ECS.

3. Cobble stop by
The same devices and information that are used to track the billets are also utilized to identify problems with
the material flow in the mill. Based on the mill layout (distances), the sequencer expects to receive certain
signals at specific times based on the active pass schedule. If these signals are not received it performs a
plausibility check using the received signals and then decides if there is a cobble. Action is then taken based
on the STOP & COBBLE conditions that are agreed upon with the customer.
Refer to cobble Strategy

4. Prevent Next Billet


Some failures in the plant cause the Signal "Prevent next billet"
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5.2.2.3.1 Chopping Strategy

General
The rolling mill contain several shears resp. choppers to chop rolling material into small pieces in case of
and shall be prosecuted.

emergencies. The reasons is to protect the mechanic against damages, and to clear the mill quickly after a
fault occurred, this means to make it ready for operation. Generally the following tasks are to fulfil:

in emergency conditions the chopping is to start automatically

the foreseen shear have to chop the complete billet

the chopping is to finish automatically after this chopping


This document is a concept for chopping. It contains the table "Chopping strategy". With this standard
solution, a complete chopping strategy will be produced as agreed with the customer, the mechanical
engineer and the planning and design team. This plant-specific strategy reduces the commissioning time.

5.2.2.3.2 Detail Function Descriptions

When is Chopping Performed


The chopping is useful in case of the following emergencies:

Communication error between the PLCs

Emergency stop resp. quick stop

Connecting error to the peripheral equipment, ET200-stations

Fault in the material flow (cobble detection)

Failure of superordinate resp. following functions

Drive error, failure of drives


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Snap shear triggered

Plant-specific special cases

Manual chopping.

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Communication Error (Class I fault)


For all communication errors chopping is automatically introduced.

Emergency Stop, Quick Stop (Class I fault)


and shall be prosecuted.

Quick stop:
In case of quick stop in a certain area the previous active shear starts chopping until material is cleared and
the mill has stopped.

Emergency stop:
In case of emergency stop in a certain area, the previous shear chops to clear the downstream area.

Faults in the Material Flow (Class I fault)


When a fault in the material flow is detected, chopping is triggered. Cobble detection is triggered by
automatic sequence control of material. The actual material position is precalculated according material
speed and evaluated by HMD and load impact signal. If material reaches thsi plausibility checks not in
certain time ("Window") chopping will be actuated automatically.

Failure of Superordinate or Following Functions


The failure of following functions has no direct effect on the chopping function. The failure triggers e.g. a
quick stop by time functions and the chopping is started if fault is not cleared. In individual cases, the
chopping can also be started directly.
Superordinate functions are e.g.:

Oil pressure for bearings and gears

Hydraulic pressure

Roll cooling

Cooling system material temperature


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The specifications of the mechanical engineer are to be observed here.

Drive Error, Failure of Drives (Class I, II, and III)


When auxiliary drives, e.g. pinch rolls, fail, normally the rolling of the material is finished. The failure of a
main drive leads to the chopping in the upstream shear.

Crop Cut was Not Executed


Chopping is not triggered.

Snap Shear Triggered (Class I)


The snap shear blocks the material flow. Chopping starts upstream of this area.

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Manual Chopping (Class I)


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Manual chopping can be started from main pulpit and several control stations. This is valid in the operating
mode Automatic only, even if the control station is not selected.
and shall be prosecuted.
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5.2.2.3.3 Fault Classification


Fault are divided into three classes:

Class I: The fault will results in immediately switch-off of the concerned drives.
and shall be prosecuted.

- Drive off: Overcurrent: Fuse blow etc.

- Chopping initiation

- Cobble detection

- Mechanical interlocks

Class II: The fault will prevent the drive from starting. If the drive is in operation, a alarm will
occur. The drive will stop after delay:

- Drive warning

- Media faults

- Interlockings; not switched on; temperatures

Class III: The fault only causes alarm, signifying lower risk condition.

- Interlocking
Refer to the relevant section for interlocking requirement for drive with hydraulic system,
lubrication system, cooling water system.

- Monitoring signal for hydraulic system and lubrication system (fault signal list).
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Table 1. Monitoring signal for the lubrication oil system of the mill. To be done by MORGAN
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Ser. No Fault designation Fault characteristics Fault Affects on main remarks


class rolling line
1 Main pump motor indication On / Off indication
2 Main pump motor overload 3 alarm Start standby
pump
and shall be prosecuted.

3 Low oil temperature 25 C, pump cannot be 3 alarm


started
High temperature 65 C 2 alarm, stop after
5 10 min. delay
4 Low oil pressure 0.1 MPa 3 alarm Start standby
pump
Low low oil pressure 0.08 MPa 2 alarm, stop after
30 s delay
High oil pressure 0.5 MPa 3 Alarm
5 High oil level in pressure 3 Alarm
tank in operation
6 Pressure difference 3 Alarm
exceeds the upper limit
7 Low high oil level 3 Alarm
High oil level 3 Alarm
Low oil level 3 Alarm
Low low oil level 3 Alarm
8 Intermediate return oil tank indication On / Off indication
pump motor
9 Intermediate return oil tank indication One pump in
Low low oil level operation
Oil level higher than 2 Alarm, stop after 2 pumps in
middle oil level in 2 min. delay operation
intermediate return oil tank
Oil level higher than high 1 Alarm, stop
oil level in intermediate immediately
return oil tank
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Table 2. Mill area hydraulic system monitoring signal.


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Ser. No Fault designation Fault characteristics Fault Affects on main remarks


class rolling line
1 Main pump motor indication pump On / Off
indication
Circulation pump motor indication pump On / Off
and shall be prosecuted.

indication
2 Main pump motor overload 3 alarm
3 Main oil port of pump indication pump
open / close
indication
4 Low oil temperature 10 C 3 alarm Change cooling
mode
50 C 3 alarm Change cooling
mode
5 Normal level indication Indicate the state
Low level indication Indicate the state
Low low level 1 alarm, stop
immediateley
6 Low pressure in main oil 3 alarm
pump system
7 Ultra high pressure in 3 alarm Circulation
circulation filter system filtering pump
stop
8 Filter clogged 3 alarm
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5.2.2.3.4 Table "Chopping Strategy"


The chopping strategy is represented in form of a table taking the following mill configuration with 7 areas
and 4 shears.
and shall be prosecuted.
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and shall be prosecuted.
Merchant Bar Mill

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5.2.3 Media Systems


The media system are situated in different cellars and places throughout the mill and provides

Lubrication
and shall be prosecuted.

Hydraulic pressure

Air Oil
to the mill area.

The following systems are placed in following places.

UHP221 Lubrication For Stand01-09 and shear 06


Lubrication For Stand10-18, Pinch Roll and
UHP222 Divide shear
UHP231 Hydraulic for Mill Stand & Auxiliary
UHP232 Hydraulic EE for Coolong Bed area
UHP219 Hydraulic EE for ROBOTS & Tilting Cradle
UHP241 Air Oil Lubrication for Mill stands.
UHP252 Grease Unit for Mill Area
UHP253 Grease Unit for Handling Area
UHP261 Contact Water- Water Pumping System

Function
All medias have to be switched on for operation (refer to 5.6 OS and drive functions)
The medias are supervised and controlled from MMI if put to AUTO.
Mill start is only possible if all Media-Systems are running and respective flow pressure is o.k (refer to the
interlocking conditions of all respective drives).
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5.2.4 Tracking

Function limits:
Start: Furnace Exit
and shall be prosecuted.

End : Bundle weighing station

Conditions:
Mill is in operation

Operator devices:
Control pulpits

Displays, messages:
Operation picture, window TRACK
Material tracking will be performed by automation systems:
Level 1: CTR ,SIMATIC S7

To perform the necessary material tracking functions the overall plant is divided into several material areas.
For example: Roughing Mill, Intermediate Mill, Finishing Mill etc.
Each area is represented by a data block in the several CPU containing specific data records for each billet,
coil.
The Level 1 CPUs such as CTR,MIL,COL generate and transfer the information for billetThere the data
records are shifted from material area to material area according to the material flow in the plant.
Events such as measured temperatures and shifting between material areas are acquired and the actual
measures are allocated to the desired record.
The material tracking is started at the exit gate of furnace
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5.2.4.1 Operation Modes:

Automatic mode
Material Tracking will be performed automatically if the desired plant areas are in automatic operation mode.
and shall be prosecuted.

Manual mode
In manual mode tracking will be performed for those material movements only which are defined accordingly
to the automatic sequences.
Every unusual material handling cannot be detected by the system and therefore not be tracked. In case of
such a manipulation of material flow, it is part of the operators responsibility to ensure that the tracking
system will be fed with updated information by manual input. The correct working of the system depends on
correct operator input.

Local mode
Generally local mode should be used only if no material is in the desired area.
If an automation area is switched to local mode (repair mode) all signals from material detectors will be
ignored by the tracking system (tracking is frozen). Before restart to normal operation it is part of the
operators responsibility to check whether the system is up to date or not.
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5.2.5 Program Structure

5.2.5.1 CTR

5.2.5.1.1 CTR: Technological Functions in the Mill Train Area


According to Charts:

CTR_RM_CHO CTR_IM_CHO CTR_FM_CHO CTR_CO_COM_XX


CTR_CO_COM_MIL_D CTR_CO_COM_COL_D EX_STD CTR_CO_GEN
CTR_RM_CO_GEN CTR_IM_CO_GEN CTR_FM_CO_GEN CTR_CO_GEN_HMDTEST
CTR_CO_DIAG CTR_CO_SCHED CTR_CO_COM_PDA SELECT
CTR_RM_SEQ CTR_IM_SEQ CTR_FM_SEQ SNAP
STXX CTR_CO_INIT CTR_CO_GEN_VISU

5.2.5.1.2 Drives switching and speed control


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There are mainly three blocks interconnected to switch modes SDV (setpoint enable devices) handle the
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speed setting REF (setpoint selection, cascade, quickstop handling) and communicate to the drives MDV
(drive communication).
They are placed in each CTR_YY_STxx (YY = Area, xx = Stand number e.g. CTR_RM_ST01) chart on
page F. There is a similar chart for each stand in the Mill.

For engineering, normally on all three blocks doesnt need to be done anything. All blocks are pre
interconnected with each other and the visualisation blocks.

The startup and run conditions are externally generated by corresponding interconnections.
The enable signals are reset when quick stop occurs and quickstop remains active at least until the drive is
stopped.

1. SETPOINT ENABLE DEVICES (SDV_KERN)


This block is used for Enable setpoint to MDV, in this block consider all
interlock related to main drive , mainly this block is connected to MDV and REF block.
The block setpoint enable supplies the signals for enabling the
automatic setpoints, the manual setpoints or the jog setpoints, dependent upon dialog operations, the
selected mode of operation and the corresponding start-up or run conditions.
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Mode of operation

The start-up and run conditions are externally generated by corresponding interconnections.
The enable signals are reset when quick stop signals occur and are not output again before a new
dialog command is given. The "Signal Quick Stop Activated" will remain active at least until the drive
has stopped.
and shall be prosecuted.

The block "Start-Up Warning" is an integral part of this module and will emit a warning signal following a
manual dialog command and will then enable the activation of the automation setpoints for a defined
length of time following expiration of the warning time. One SDV_KERN is required for each drive and
one SDV_STW for each control pulpit area.The output interface STA_ENB of the SDV_STW must be
wired to the input interface STCN_AUT of all SDV_KERN.

The output interfaces of the module SDV_KERN must be connected to the corresponding input
interfaces of the module REF_KERN, allocated to the drive, of the same name.

Select Mode of Operation "Automatic"


The "START GROUP" (STA_GRP = 1) will start all the equipment allocated to the group (stands, roller
tables, pinch rolls, etc.) that are designated as "
Selected" in the pass schedule and whose start conditions are fulfilled.
The inverter enable signal (INV_ENB) is output and the enable signal for the automatic setpoint (AU_R)
is output as soon as the signal drive ready to run (RDY_RUN) is active.

One of the necessary start conditions is the signal "STA_ENB", and is output by the start-up warning
block SDV_STW for a configurable time period following expiration of the start-up warning time. The
group can consist of a complete automation area. Several groups can also be designated as one
automation area.
All the equipment allocated to a group is stopped by the signal "NO STOP GROUP" (NST_GRP = 0).
This implies that the enable signals for the automatic setpoint and the inverter are set to zero. The
prerequisite is, that the deactivation of the inverter enable in the downstream start-up control block, can
be delayed by a configurable time period in order to permit the defined braking of the drive
(corresponding to a setpoint ramp). This also prevents magnetization and demagnetization of the drive,
in jog mode, between sequences of jog commands.

The corresponding equipment is started by the signal "SINGLE ON" (STA_SNG = 1), when it is
designated as "Selected" in the pass schedule and the start conditions are fulfilled (review "START
GROUP").
The corresponding equipment is stopped by the signal "NO STOP SINGLE" (NST_SNG = 0), review
"NO STOP GROUP.
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If the "Selected Signal" is overwritten by a new pass schedule transfer, then the corresponding piece of
equipment is stopped (review "NO STOP GROUP"). The pass schedule transfer is only permitted with
an empty mill.

Equipment, that is additionally "Selected" in a new pass schedule (i.e. previously not "Selected") are not
started by the pass schedule transfer, but only through operator dialog from "START GROUP" or
"SINGLE ON".

Select Mode of Operation "Manual"


The corresponding equipment is started by "SINGLE ON" (STA_SNG = 1), when the run conditions
(RNCN_MAN = 1) are fulfilled. The inverter enable signal (INV_ENB) is therefore activated. The enable
signal for the manual setpoint (MN_R) is output as soon as the signal drive ready (RDY_RUN) is active.

The corresponding equipment is stopped by the "NO STOP SINGLE" (NST_SNG = 0). This implies that
the enable signals for the manual setpoint and the inverter are set to zero.

Select Mode of Operation "Maintenance"


The corresponding equipment is started by "SINGLE ON" (STA_SNG = 1), when the run conditions
(RNCN_MNT = 1) are fulfilled. The inverter enable signal (INV_ENB) is therefore output. The enable
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signal for the manual setpoint (MN_R) is output as soon as the signal drive ready (RDY_RUN) is
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activated.

The corresponding equipment is stopped by the "NO


STOP SINGLE" (NST_SNG = 0). This implies that the
enable signals for the manual setpoint and the inverter
are set to zero.
and shall be prosecuted.

The drive can also be jogged if the input interface


"INC_CENT" is set.
The corresponding equipment is started by "JOG
FORWARDS" (INP_COM = 1) when the run conditions
(RNCN_MNT = 1) are fulfilled. The inverter enable
signal (INV_ENB) is therefore output. The enable
signal for jog forwards (INP_R) is output as soon as
the signal drive ready (RDY_RUN) is activated.

The corresponding equipment is started by "JOG


REVERSE" (INM_COM = 1) when the run conditions
(RNCN_MNT = 1) are fulfilled. This implies that the
inverter enable signal (INV_ENB) is output. The enable
signal for jog reverse (INM_R) is output as soon as the
signal drive ready (RDY_RUN) is activated.

Select Operating State "Local"


If the input interface "LOA" is set, then the drive can
only be jogged via the input interfaces INP_COM and
INM_COM. The interlocks must be implemented in
front of this interface when mixed operation is set, i.e.
"Local" and "Central" jogging.

The corresponding equipment is started by "JOG


FORWARDS" (INP_COM = 1) when the run conditions
(RNCN_MNT = 1) are fulfilled. This signifies that the
inverter enable signal (INV_ENB) is output. The enable
signal for jog forwards (INP_R) is output as soon as
the signal drive ready (RDY_RUN) is activated.
The corresponding equipment is started by "JOG
REVERSE" (INM_COM = 1) when the run conditions
(RNCN_MNT = 1) are fulfilled. This signifies that the
inverter enable signal (INV_ENB) is output. The enable
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signal for jog reverse (INM_R) is output as soon as the


signal drive ready (RDY_RUN) is activated.

Local Operating State "Group" and "Single"


A positive edge at the interface GROUP will activate, for the single drive, the operating state of the
corresponding drive group. The mode of operation is also switchedthrough as described above. If the
individual drive is switched to the operating state "SINGLE" (= "Maintenance"), i.e. positive edge at the
interface SINGLE, then only the conditions that correspond to the mode of operation "Maintenance" can
be implemented.

Miscellaneous
If several operator stations are to be installed, then the signals "SINGLE ON" (STA_SNG = 1), "NO
STOP SINGLE" (NST_SNG = 1), "JOG FORWARDS" (INP_COM = 1) and "JOG REVERSE"
(INM_COM = 1) from the various operator stations must all be interconnected via external wiring and
interlocked corresponding to the operator station selection.
If the inverters dynamic enable of (i.e. enable with the setpoint enable) is not necessary, then the
inverter can be enabled simultaneously with the start-up command (electrical power-up) by the start-up
control block. The output signal INV_ENB is then not utilized.

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The start and run conditions for the enable of the automatic setpoint (STCN_AUT and RNCN_AUT), for
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the enable of the manual setpoint (RNCN_MAN) as well as for the enable for the jog setpoints
(RNCN_MNT) must be externally generated from the corresponding individual signals.
All enable signals (AU_R, MN_R, INP_R, INM_R and INV_ENB) are set to zero, when QST = 1 or
LOCK_SW = 1 or NES = 0 or NEO = 0.
and shall be prosecuted.

2. REF_KERN Reference main drive kernel


Main drives setpoint generation, cascade controller and stand individual adjustment

The function of the setpoint generation is to pass a valid rotational speed setpoint to the drives in different
operating modes.

The cascade controller, as an integrated component, enables the


coordinated speed correction of a mill section starting from a selected
stand. The speed of the selected stand is adjusted, whereby speed
relations of the other stands taking part in the cascade are
maintained. The rate of the speed modification takes place upward
and downward in each case in two steps (two different ramps). (The
steps are adjustable over pre-stored values, not changeable without
special authorization in the HMI).

The stand individual adjustment enables the speed correction of


individual stands. The rotational speed of the selected stand is
adjusted, without influencing the speeds of other stands.

The rate of the rotational speed modification takes place upward and
downward in each case in two steps as in the case of the cascade
adjustment.

The cascade adjustment, as well as the stand individual adjustment,


operates only in the operating mode automatic.

Auxiliary drives

Via the module REF_AUX_DR only roller tables and drivers are
supplied with a speed reference. Shears are treated in a separate
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function.

Auxiliary drives are assigned speed-wise to a master (usually a main


drive), whose speed they follow with a leading factor.

Mode of operation

Setpoint generation
The function of the setpoint generation is to pass a valid speed
setpoint in different operating modes to the drives.

Operating conditions
In the operating mode automatic the setpoints comprise of the
setpoints which are located in the operating buffer of the pass
schedule as well as the additional setpoints of cascade
adjustments, stand individual adjustment, automatic controllers
and passed-through values of neighboring stands. The release of
the setpoints is effected via the signal automatic setpoint release
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(AU_R) from the switch-on block (SDV). The enabling signal is interlocked in the switch-on block with the
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condition drive selected (SEL).

The information whether a drive is selected, is contained in the pass schedule and tis availability is
updatedin the operation buffer. The selection of the drives can be modified optionally on-line via the
visualization system. After a new pass schedule transfer, the selection contained in the pass schedule
becomes effective.
and shall be prosecuted.

After automatic setpoint release (AU_R) or a setpoint modification of the setpoint (NSC), given by the
pass schedule, the setpoints are fed through a ramp with the internally stored normal slope, until the ramp
output value is equal to the ramp input value. Starting from this point in time the ramp output follows the
ramp input instantaneously.

When leaving the operating mode automatic or reset of the automatic setpoint release AU_R, the drives are
stopped. Internal memory (optimized additional setpoints of the automatic controllers) and ramp generators
for cascade / single adjustment are not modified when switching off the automatic mode, so that these
changes are retained upon restart.

Individual switching on/off


In automatic operation it is possible to switch on or off the release of the automatic setpoint for individual
drives. It is also possible to switch drives individually into the operating mode maintenance, even if the
corresponding area is switched in the operating mode automatic.

In the operating mode maintenance the drive jogging setpoints (RIP or RIM) or an adjustable manual
setpoint (RMN) from the visualization system, can be passed via a ramp. The jogging signals (INP and INM)
as well as the enabling signal for the manual setpoint (MRS) are supplied by the switching on block (SDV).
The jogging setpoints or the manual setpoint are output so long, as the respective signals are applied.

Auxiliary drives get their own jogging setpoints (see jogging).

With quick stop the setpoints are driven to zero, whereby the speed relations are maintained. The slope of
the ramps depends on the drive with the longest deceleration time, whereby the shortest possible
deceleration times (steepest brake ramp) of the individual drives are used for the calculation. A quick stop
function in progress cannot be interrupted and is terminated basically when speed zero is reached.

The same applies to normal stopping of the drives by resetting the automatic setpoint release (AU_R). Here,
however the normal deceleration time (normal brake ramp) of the individual drives is used for the
calculation.
Quick stop is effective also in the operating mode maintenance.
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When jogging this function is not relevant.


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For auxiliary drives, the main drive supplies the Material speed (MSO). The material actual speed is
determined by multiplication of the set rpm of the main drive with the rpm-speed factor (SVF).

Inactive stands (dummy stands)


Due to modifications of the mill configuration, switched off stands (not selected stands) are designated as
dummy stands. For a dummy stand the setpoint of the preceding stand is used.
However, the speed-setpoint is not output to the drive.

Cascade controller and stand individual adjustment

The cascade controller enables the coordinated speed correction of whole mill sections starting from a
selected stand. The speed of the selected stand is adjusted, whereby speed relations of the other stands
taking part in the cascade are maintained. The rate of the speed modification takes place upward and
downward in each case in two steps (ramps), adjustable over pre-stored values, not changeable without
special authorization in the HMI. The cascade adjustment is possible only in the operating mode automatic.

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The effect of the cascade typically goes from the selected stand toward mill entry (upstream) up to the first
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stand.

Particularly with multi strand mills, however, several cascades independent from each other are to be
implemented, whereby the direction of action as well as mill exit direction is needed.

If the rotational speed of the following drive becomes smaller than 20 rpm, then the intervention factor at the
and shall be prosecuted.

drive concerned is made zero and thus the cascade is interrupted here.

Thus the speed relation between the drives can become disturbed.

If a drive reaches its positive speed limit value, then for the entire cascade area a cascade adjustment is
blocked in the positive direction. (Example: If stand 5 is at the upper speed limit, then the cascade cannot be
driven upward even after the selection of stand 3.) This applies also to drives of the cascade area that are
manually switchedindividually, since they are involved in the cascade adjustment in the background.
Although they are operated with the manual setpoint or are stopped, a limitation of the cascade adjustment
is enabled, if the automatic setpoint (FNR), in the background reaches the limit speed value of the drive.

The stand individual adjustment enables the speed correction of individual stands. The selected stands
speed is adjusted, without influencing the speeds of the other stands.

The rate of the speed modification takes place upward and downward in each case in two steps (ramps) as
in the case of the cascade adjustment.

Cascades are operable at the same time at several locations. However, cascades may not overlap, only the
leading stand can serve as a stand simultaneously in several cascades (e.g. multi strand mill).

For better explanation


A single strand mill consists basically of a cascade, with the exit stand is the leading stand. An operation of
this cascade at several control locations (even simultaneous) is admissible. The stands of the cascade,
however, are assigned to a unique control location for the operation. Each control position thus possesses
the selector push buttons for its assigned stands, as well as individual selector switches for cascade and
individual adjustment and the appropriate push buttons for "faster" and "slower".

Example:
A cascade is operated at control location 1 and control location 2. The stands 1, -10 are assigned to control
location 1 and the stands 11 - 18 to the control location (pulpit) 2.

If the speed relation between stand 13 and 14 is to be adjusted, then stand 13 should be selected and
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during selected cascade adjustment, the speed of stand 13 varied via the push buttons faster or slower.
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Also the speed of the stands 1 to 12 are adjusted in the same relation, so that the speed relations of the
stands 1-13 are preserved.

A simultaneous speed change of one of the stands 1 to 10 from control location (pulpit) 1 is possible,
independent of the function selection on operating pulpit 2. Individual or cascade adjustment can be
selected.

Material exit velocity


The material exit velocity is calculated by multiplication to the drive supplied speed setpoint and the speed
rate conversion factor (SPEED_VELOCITY_FACTOR). The material exit velocity is output to the following
stand (drive module). If this stand is not active (on), then the exit velocity supplied by the previous stand is
output as this stands own exit velocity.

Calculation of the ramp slope


For each drive, the ramp slope for quick stop (QIT = deceleration time of rated speed to zero at max torque)
and normal starting and stopping (SST = run-up period or deceleration time of zero to rated speed or rated
speed to stop, at selectable smaller torque. This has to be adjusted during commissioning).

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With automatic setpoint release (AU_R), with renewed setpoint generation after pass schedule transfer or in
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maintenance operation the SST ramp is used to ramp to the new setpoint.

With quick stop on each drive by the adjusted time QIT and the current drive speed, the actually needed
time is calculated and output at OST.

The largest time OSTmax, output at OST, is selected and linked to TBR again. To calculate the time
and shall be prosecuted.

(OSTmax), linked at TBR, all OSTs used in the current process are compared to find the largest value. At
the ramp block this ramp slope is to be indicated as run-up period of zero to rated speed.

With the automatic setpoint release out (AU_R), calculated on each drive by the adjusted deceleration time
SST and the current drive speed, the actual needed deceleration time Tna is calculated and output at OST.

Auxiliary drives are not included into the min./max analysis. Roller tables are not material conclusive, pinch
rolls have a better acceleration/delay behavior than main drives and shears are always treated separately.
This one is placed on each STDXX chart on page F2.

3 SIN_MDV Drive interface to SINAMICS

The block executes the interface to the SINAMICS and works


together with the switch on module SDV and the drive
reference value module REF.

Mode of operation
The Block calls internally a group of blocks from the TMBASE
library blocks which are necessary to link a simple speed
drive to the CSM and the reference value system.

The block links the basic automation (S7) to a simple speed


drive via PROFIBUS by an internal call receive block SFC14
and the send block SFC15 for L2DP telegram.

The functions of central switching and monitoring CSM are


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carried out by an internal function. The block executes the


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link to HMI reading the commands for switching the inverter


and supplying the information of drive status for HMI. For
switching the inverter, the block writes to the drive control
word. Thereby the block evaluates the start, stop and running
conditions for the drive as well as emergency functions and
the status telegram from drive. The switching of inverter is
supervised by monitoring time CSM_TS. The inverter enable
as well the set point enable are switched with adjustable
delay times CSM_TE, CSM_TD.

The scaling of the drive setpoint values and actual values


from drive is accomplished by an internal function. Physical
setpoints are scaled and actual values converted into
physical quantities.

The operation time of drive is counted by an internal function.

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The block drive, interface to SINAMICS, SIN_MDV offers a drive simulation for engineering by switching the
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input ENG_SIM to simulation mode. In case of the command ENG_SIM, the inverter decelerate to stop by
setting bit ON to 0 (S_PZD1), the drive is switched off, L2DP-communication is cut off. The receive telegram
from drive is not evaluated, the drive functions are simulated.

Furthermore the block SIN_MDV generates the commands for drive control word 2 and supplies all drive
data for the send L2DP telegram. Moreover the block evaluates the status L2DP telegram from drive and
and shall be prosecuted.

supplies the corresponding data for the basic automation.


This one is placed on each STDXX chart on page F3.
4 VISU_MD_A Visualization main drive part A
This one is placed on each STDXX chart on page B1 , this block is interconnected to SDV , Ref and
MDV block .
The blocks link all data to be displayed, per drive object (inputs and outputs), to the HMI system (i.e.
WinCC). A differentiation is made between ONLINE data and parameters (only for maintenance purposes).

New data is copied to the ONLINE data by the signal NEW SCHEDULE (NSC) at a pass schedule
change. In addition, all necessary data is made available for restoring to the modification buffer.

Format conversions (i.e. from REAL to S5 TIME) are implemented and static dialog signals deleted from the
HMI when necessary. Conversion from imperial units (i.e. feet, inch, mph, ...) to SI units (i.e. m, cm, km/h) is
exclusively implemented within the HMI.

Mode of operation
The rolling schedules and customer data transferred from level 2 can be modified by the operator in the
modification buffer and transferred to the operation via the command New Pass Schedule to the Operation
NSC.The design also accommodates that the current operational data (as optimized values) can be
returned directly to level 2 via the command Return Optimized Data OPT or intermediately saved in the
modification buffer via the command Restore Saved Data into the Modification Buffer SAV.

Pass Schedule: The pass schedule, in the context described here, is all the data required for production of
a defined material. Several different pass schedules exist within the pass schedule administration. Only one
of these different schedules at a time can be transferred to the modification buffer by the operator.

Modification Buffer: Buffer between the pass schedule and the operational data, into which a pass
schedule, either received from level 2 or entered via the HMI system by the operator, can be saved. The
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operator can change and modify, when required, the data set in this buffer via the HMI. The modification
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buffer can be transferred to the operational buffer via operator dialog.

Operational Buffer: The data set currently being processed within the mill.

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and shall be prosecuted.

5 VISU_MD_B Visualization main drive part B


This one is placed on each STDXX chart on page B2, he
block links all data to be displayed, per drive object (inputs and outputs), to the HMI system (i.e. WinCC). A
differentiation is made between ONLINE data and parameters (only for maintenance purposes).
Format conversions (i.e. from REAL to S5 TIME) are implemented and static dialog signals deleted from the
HMI when necessary. Conversion from imperial units (i.e. feet, inch, mph, ...) to SI units (i.e. m, cm, km/h) is
exclusively implemented within the HMI.
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contrary to its intended purpose is not permitted
and shall be prosecuted.
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6 MinimumTensionControl(MTC)

Tension between two stands requires torque from the stand motors. This torque is calculated by the drives
based on the measured motor current. That means, that the motor torque, delivered by the drive system can
be used as an indicator for tension (or push).

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When a bar enters a stand (actual stand), the motor torque of that stand is an indicator for the required roll
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force.
When the bar enters the next stand any changes in the motor torque of the actual stand would indicate
tension (or push).
After having a proper torque reading, the MTC will calculate based on the torque difference and the
reference value for the tension a change of the speed setpoint. In order to adjust the speed setpoint to the
set value, the speed setpoint of the actual stand will be modified including the upstream cascade. By doing
and shall be prosecuted.

this, push will be avoided and the tension will be limited to the reference value.
Most important for a proper working MTC is the right sequence of the measurements. The first and second
measurement of the first stand need to be finished, before the first measurement of the second stand can
start.

If the time a bar needs from one stand to the next stand is less than 0,7 sec, the calculated change of speed
will be used for the next bar and not for the current bar. The advantage for the mill operation is that for the
next bar all stands will operate with speed setpoints corrected based on proper torque readings. Specifically
for the first few bars after roll change, the MTC will optimize the speed settings very quickly. However, the
operator also has the option to choose the immediate action of MTC. This could be beneficial, after having
the mill properly set, to compensate little temperature deviations or other minor disturbances, which are
normal during rolling.

Additionally to the MTC the operator has the option to manually optimize the speeds of the stands via the
cascade control or via modifying the pass schedule. This option could be very beneficial for new products
or other rare situations.
The minimum tension controls in the mill train act in the same direction and opposite to the rolling direction,
i. e. any possible control disturbance drifts into the non-critical entry area.

The minimum tension control will only be used in a single strand mill.

The minimum tension control system (MTC) is realized in the block MTC_KERN. This one is placed on each
STDXX chart on page C1.

For engineering the MTC control the first decision you have to make is weather to use current or torque
feedbacks. You select it by the input SE_TO_CU ( select torque or current).
The next thing to do is checking the input ST_OC_UP (material in this selected stand).
The TP_OCCU signal of this stands tracepoint need to be connected to here.
The last thing for engineering to do is to connect the input HEAD_RT (Billet head running time). The block
needs to know the time from this stand to the next stand. Therefore add together all head running times
provided by the sequencer blocks and connect the result to this input. For example you have a configuration
like following: stand 6, cut HMD, shear, HMD, stand 7. Then you have to add together the outputs
RT_HEAD of the block SEQ_KERN of the tracepoints stand 6, cut HMD, shear and HMD.
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Description of MTC_KERN***************************************************************************

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contrary to its intended purpose is not permitted
and shall be prosecuted.
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Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

*********************************************************************************************************

Already during engineering the MTC can be setup 90% correctly. Therefore its important to input a valid
rolling schedule as soon as possible. Based on this you can set the points for the first and second
measurement already for simulation.
The first point will be set by the input FACT_F_M (factor first measurement). Its a value between 0 and 1. A
setting of 0.5 would mean that after the signal ST_OC_UP a calculated time 0.5 x HEAD_RT later the first

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measurement will be done.


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The second measurement is more a constant. Normally you have to find out the time the drive needs to
recover from the impact. This time need to be written to the input IMPACT_T (impact drop compensation
time) The best way is to check the recordings of the PDA system and with this information set the timevalue.

*********************************************************************************************************
and shall be prosecuted.
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*********************************************************************************************************

Small tip, for the display of MTC active most time the output MTACTION is used. It can happen that even
the MTC correction was done, the display dont show the activity. In this case use the binary output
MTACTIV for the display.
Another thing is the input MAN_INT. Everytime a manual cascade intervention will be done, the MTC control
will be blocked. For example if a first measurement was done and before the second one can be done a
manual intervention happens, then the MTC will be stopped and no additional speed value will be output for
this billet head.

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5.2.5.1.3 Cobble Detection and Control of the Chopping Shears


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If a cobble occurs the shears in front of the mill train is automatically started to chop the material.
Occasionally snapshears will be closed to protect important equipment. The bar entry into the roughing mill
will be blocked.
Cobble detection is provided for the roughing mill train, the intermediate mill train, and the finishing mill train.
Basically the travelling time of the head of the bar through a mill train is detected and compared with a
and shall be prosecuted.

speed dependent reference time. If the tracking system detects a fault on two trigger tracking points in a
row, then cobble detection will be activated and the
corresponding action will take place.

Mainly this part is included in the charts CTR_RM_CHO (Roughing Mill), CTR_IM_CHO
(Intermediate Mill) and CTR_FM_CHO (Finishing Mill).CHOCONTM_A(NTM A Area) CHOCONTM_B(NTM
B Area)

The pages B1 and C1 create a signal for the stands to determine if an area to which a stand belongs is in
chopping mode or not. The block TP_CHOP is used to create this signal.

Description of TP_CHOP*****************************************************************************
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*********************************************************************************************************

In B1 for each stand, HMD or Loopscanner one block is interconnected with each other in
upstream direction, this means from the last stand in the area to the first stand. In C1 the same is done only
in downstream direction.
Important to activate this detection is to connect the corresponding shear chopping signal (for example
DB760.SH2_CHOP to the input CHOP of the first block in the sequence.
B1 and C1 are only used for determination of chopping in an area. This generated signal will be used in
other places to force reactions (e.g. freeze LOOP control, retract pusher)

The program on page D is used to detect a cobble in the area and to trigger an reaction.
Therefore there is, on page D1, for each stand, HMD or Loopscanner one COBBLE block interconnected
with another in downstream direction, this means from the first stand in the area to the last stand.

Description of COBBLE*******************************************************************************

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and shall be prosecuted.

*********************************************************************************************************

The tracepoints in the SEQ charts deliver according to a runtime supervision the input HWTR_NOK. As
soon as two of the blocks in a row, activated by setting TRIGG_ON to 1, detect hardware trigger not ok a
cobble signal will be generated.
The first HWTR_NOK signal in an area causes no problem. With it the output COUN_OUT will be set to 1 if
the trigger is activated. If the next block doesnt get a HWTR_NOK signal, the output is reset to 0, nothing
happens. But if it also gets the HWTR_NOK signal the counter is set to 2 and the cobble signal generated.
With this a message will be send and the reaction started.

TRIGG_ON should only be set to 1 for HMD and Loop scanner, never for stands.
The cobble detection itself can be switched on and off from the HMI. Normally it is active for the Finishing
area, inactive for the Roughing and Intermediate Mill. The more trigger tracepoints you have, the better and
faster the cobble detection can work.

On D2 the cobble signals are collected and together with the signals SCRAP_AUT (stand not ready for
rolling) from all stands of the following area and maybe snapshears closed or shear not ready signals they
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will start the shear in front of this area to start chopping and will set a prevent next billet.
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For engineering its important to have all tracepoints (stands, HMD, Loopscanner) in the right sequence in
the program.

5.2.5.1.4 Communication

There are 3 ways of communication in the program.

1. Profibus connection to the drives and the PDA system.


This connection is defined and parameterized in the Hardware and the charts L2-DIAG and SELECT.

The addresses defined in the hardware need to be written in the SELECT chart to the corresponding blocks
on page D.
The error bit for each profibus address defined need to be written in the L2-DIAG chart to the corresponding
blocks on page C.

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Please check during engineering the parameterisation of the profibus error detection block CTR_CO_DIAG
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in chart L2-DIAG on page B1.


Its main functions are to generate diagnostic information for:-
- Profibus
- External ET200 Faults (Fuses)

Description of DIAG_L2******************************************************************************
and shall be prosecuted.

*********************************************************************************************************

According to the hardware setup the L2_ID (address of the profibus communication device) need to be
adjusted together with the INT_EXT input, which determines internal or external connection.

For example there is a drive with profibus address 7 and this one is connected to the internal CP connector
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which is defined in the Hardware with the address 1. In this case the bit DB535.DP1_ERR_SL_7 can be
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used in the program to determine weather the profibus connection to this drive system is disturbed or not.

2. Ethernet communication
This connection is defined and parameterized in the Hardware, the Connections and the chart
CTR_CO_COM_XX (where XX is the partner CPU name) e.g. CTR_CO_COM_COL when CTR is
commnunicating with COL CPU.
All data preparation for sending & receiving is done in corresponsing chart CTR_CO_COM_XX_D.

In the Hardware you define for the CP443-1 which kind of Ethernet communication will be used. In our mills
we normally use ISO/OSI which means you have to define a Ethernet MAC address. But a TCP/IP
connection would also work without the necessarity of changing the program.
In the connections all partners of this CPU need to be set up.
In the chart COM there are send and receive blocks for every connection included.

Description of Send Receive***********************************************************************

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*********************************************************************************************************

One connection can consist of several send and receive blocks (like CTR-SHE one for schedule data, one
for actual data). During engineering check that the ID of the communication blocks is according to the
setting in the connections (ID may change if connection table is changed)
The R_ID on both CPU of one connection need to be the same, but it is only allowed to use it once in the
project. Take care for the length setting LE_S of the DB, especially after changing the communication DB.
There is always a sending and a receiving DB for one connection, for example DBCTRSHE (sending from
CTR to SHE) and DBSHECTR (receiving CTR from SHE). These two data blocks have to be the same in
both CPU.

Tipp: if the communication block shows an error, but the physical connection itself is ok, then set input
PULSE/MON_TIME at the communication blocks to 0 on both sides.

5.2.5.1.5 Schedule handling

The schedule handling is a own closed complex in the program. Changes on the structure of the schedule
DB are not allowed. If additional data need to be send or received to or from the schedule, it need to be
added. The original structure need to be kept.

Basically the schedule standard is designed for


- one Roughing mill area with 8 stands, 2 shears, 2 pinchrolls, 2 RT, 2 Cooling zones
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- one Intermediate mill area with 8 stands, 2 shears, 2 pinchrolls, 2 RT, 2 Cooling zones
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- one Finishing mill area with 8 stands, 2 shears, 2 pinchrolls, 2 RT, 2 Cooling zones
- one Wire rod mill area with 2 finishing blocks, 2 shears, 2 pinchrolls, 1 laying head,
6 waterbox zones
- one Cooling bed area with up to 20 drives

The schedule can either be received by ISO/OSI communication from a Upper Level system or from the
HMI WinCC archive.

The basic handling is done in chart CTR_CO_SCHED and is as shown below:-

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Schedule / Parameter handling chart functions:-


- Receive schedule
- Receive parameter
- Send optimized schedule
Following are the 3 DBs which are used for data transfer:-

1. DBARCCTR Acrhive DB. This DB is linked to fields in WinCC User Archive.

2. DBMODCTR Modification DB. This DB is the data in modification screen.

3. DBOPECTR Operation DB. This is the Operation Data.


COM is the command from the HMI.
Below are the block in cfc which manages data transfer:-
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Under each stand chart e.g. CTR_RM_STD01, there is VISU_A block which transfer data from modification
to Operation. The input arrives on structure variable SCHED and the output Y are the operation parameters.
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5.2.5.1.6 Sequence Control, Head and Tail Tracking


Depending on the position of the head/tail of each bar the necessary enabling and inhibit signals are
provided for:
setpoint setting
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minimum tension control


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loop control
initiation of loop pusher
start of shears (cropping, chopping, sample cutting of front and/or tail crop cuts and dividing functions)
sequence control for roller tables, pinch roll, material transport and etc.
open/close of valves for stand roll cooling

The billet tracking has the task of tracking the positions of the billet head and billet tail within the mill area.
Dependent on the calculated expected positions of the billet heads or billet tails it generates signals to
validate the HW signals coming from the mill. These HW signals are formed by photoelectric cells, load
signals of the drives or shear-cut signals. These signals indicate the current billet position. The generation of
the validate signals is called plausibility check, which serves to screen out incorrect signals.

Basically the tracking is also divided into areas, which are interconnected. The charts CTR_RM_SEQ,
CTR_IM_SEQ, CTR_FM_SEQ and CTR_CO_GEN_HMDTEST work together for the tracking.
SEQ functions are:
- material head- and tail tracking
- cobble detection

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- ghost rolling
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By selecting SIMULATION on HMI for an area and then START/STOP there will be
a endless billet started in Intermediate and Finishing Mill or continuously coming/going billets for Roughing
Mill.
The time for billet run and gap time can be adjusted in the program in chart SEQRM on page B1.
and shall be prosecuted.

If simulation is selected in more than one area in a row, the simulation only need to be started in the first
area and will automatically continue into the next one.
The program is written in that way that in case of prevent next billet signal, the simulation in Roughing Mill
will be stopped until the problem leading to the fault is solved. This should teach the customer from the
beginning to have a look on the prevent next billet signal and not to roll by ignoring it.

The backbone of the whole tracking is one block, the SEQ_KERN. It represents one so called tracepoint. A
tracepoint can be a HMD, a loopscanner , a stand or a shear.

You can divide into different kind of them:


1. Triggering tracepoint. HMD and Loopscanner and shears are some. At this point the tracking will be reset
to the OWN_LOC value of the position of the tracepoint, triggered by the hardware signal or cut or chopping
signal.
As long as the tracepoint is a trigger point, the input HW_TRIGG will be used. SW_TRIGG
has no meaning in this case.
For engineering as trigger point set TRIGG_ON to 1.
2. Speed changing tracepoint. Stands are speed changing tracepoint. The speed and therefore the rate of
the calculated tracking is increasing.
As long as the tracepoint is a speed changing point, the input SW_TRIGG will be used. HW_TRIGG has no
meaning in this case.
For engineering as speed changing point set SPEED_ON to 1.

3. Combined trigger and speed change. Stands with available or self made stand load signal can be a
combined trigger point.
The input HW_TRIGG will be used.
For engineering as combined point set TRIGG_ON to 1 and SPEED_ON to 1.
4. Dummy point. For no real use, just to keep in program. But remember all positions, especially the
OWN_LOC, still need to fit, otherwise the tracking will be wrong.
The input SW_TRIGG will be used.
For engineering as dummy point set TRIGG_ON to 0 and SPEED_ON to 0.

Description of SEQ_KERN***************************************************************************
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*********************************************************************************************************

Basically for working with the tracking is the window technique. There are two kind of windows, external and
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internal ones.
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To use internal windows, set input EXT_WIN to 0. Then the inputs H_WIDTHM, H_WIDTHP,
T_WIDTHM, T_WIDTHP will be active and open or close the head and tail windows according to the
distances defined there. Internal windows are always limited for opening by the position of the tracepoint
before and for closing by the position at the counter end (OWN_LOC plus COUNTEND).
To use external windows, set input EXT_WIN to 1. The inputs HEAD_WIN and TAIL_WIN will be active. If
they are fixed to 1 the windows will always be open and will accept a trigger signal anytime. But its also
possible to connect a logic to open and close the window. With this a bigger window range would be
possible than with internal windows.

Important, the window for the first, secure triggerpoint, normally HMD before or after stand 1 has to be
always open to accept a new hardware signal.

Just to remember, working with windows can also be a risk. If the tracking goes wrong for some reason, the
calculated position will be wrong and therefore windows will probably open and close the wrong time so that
a coming or going hardware signal may not be accepted by the system because the window is closed at that
moment. This can cause either an endless billet or no new billet head. Both cases normally lead to cobbles.
This means you have to use and set windows carefully. Always consider all cases, fast and slow rolling,
small and big billet gaps.

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The minimum requirement so that the tracking is working, is additionally the interconnection of following
in/outputs:
TracePoint1 (TP1) to TP2: HEADCOUN to PR_HCOUN, TAILCOUN to PR_TCOUN, OWN_LOCA to
PREV_LOC, END_COUN to END_PREC, MS_H_OUT to MS_HEAD, NEXT_OCCU to SW_TRIGG (for
stands, shears also to HW_TRIGG)
TP2 to TP1: MS_T_IN to MS_TAIL, OWN_LOCA to NEXT_LOC
and shall be prosecuted.

Output HWTR_NOK to the corresponding block in the chart CHOCOXX.


In areas where MTC is used, output RT_HEAD to the block MTCADDTIMES in the STDXX chart.
In areas where LOC is used, output RT_HEAD to the block ADDHEADRT and output RT_TAIL to the block
ADDSRTTL1 in the STDXX chart.
For HMDs and Loopscanner output SIM_OCCU to the corresponding block in the chart HMDTEST.

Most important is the output TP_OCCU for the stands. This one need to be connected to
following places. Please always counterscheck this.
Here as example for stand 14:
- chart EXSTD, block ST14, input OCC
- chart STD14, block SLI, input SUO
- chart STD14, block MTC, input ST_OC_UP
- chart STD14, block LOGSW, input OW_ST_UP
- chart STD13, block SLI, input SDO
- chart STD13, block LOGDO, input OW_ST_DO
- sometimes if used as reference point for loop control, then additional to input R_TP_OC of
block LOGSW of (for example) STD17
There are two ways of HMD test possible in the system. One is included in the SEQ_KERN block, another
one is realized in the HMDTEST chart.

The SEQ_KERN HMD test can only be done in the modus maintenance, this means the drives will be
stopped. You dont need to be in the modus simulation. But this is a disadvantage if you just want to test a
HMD in between production.
The HMDTEST allows you to do a HMD test with running drives. But its better not to be in simulation mode.

Both test follow the same principal, with activating test, a hardware signal, connected in chart HMDTEST,
will be output to the HMD. The HMD is sending back the normal hardware detect signal. This signal is
connected to the SEQ_KERN block and the HMI will display the material detected.
For HMD TEST there is Screen on HMI for Enable the HMD test ,the following block is used to test HMD
from HMI
The logic for HMD TEST is mention in HMDTEST chart
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5.2.5.1.7 LOOP Control In this mill there are total 3 up looper and 2 side
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looper

Uplooper 1 before std 12

Uplooper 2 before std 13


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Uplooper 3 before std 14

Uplooper 4 before std 15

Uplooper 5 before std 16

Uplooper 6 before std 17

Uplooper 7 before std 18

Following Block is LOC_KERN Loop controller


The looper control is given the task of influencing the
speeds of neighboring stands such that a defined material loop is
formed between the stands; hence the material is rolled in a tension
free state.
The setpoint for the height of the loop is defined via the HMI
system. The loop height actual value is given via the loop position
encoder.

A selection permits definition of whether a supplementary value


from the LOC will only act upon the assigned stand or via the
intervention logic to all drives lying in the operating direction
(upstream) of the looper control, right up to the end of the billet.
This functionality is, however, implemented in another module
(SLI).

Each individual LOC can be switched to the active / inactive state via
the HMI system.

The LOC is deactivated should chopping occur.


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The loop formation is simulated via LOC internal simulation when the
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state "Simulation" or ghost billet is selected.

The control of the looper utilities (pusher, guides, dampers etc.) is


functionally implemented in the LOC. The timeing point for the
control of these utilities is independent from the activation and
deactivation of the controllers (example: the pusher must sometimes be activated before and sometimes
after deactivation of the loop). This implementation is project specific.

Special utilities (dampers, guides) are project specific.

Mode of operation
The feed through of the LOC is not implemented in the LOC, but rather in the function Adaptation and Feed
Through Logic SLI.

A selection determines whether the supplementary value originating from the LOC will be switched to the
corresponding stand or to the feed through function.

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An evaluation factor for the transfer of the optimized supplementary setpoint is located in the function
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Adaptation and Feed Through Logic SLI (fixed evaluation factors such as an interface to the module;
cannot be modified in the HMI).
Each individual LOC must be capable of being independently switched to active / inactive. This also applies
to each individual adaptation within the LOC.

The LOC is deactivated when chopping occurs. The output supplementary setpoints are maintained until the
and shall be prosecuted.

end of the billet and the outputs continued even after transfer into the non-active state. A previously saved
optimal speed supplementary value remains intact (component of the adaptation SLI).

The loop formation is created via an LOC internal simulation when the state Simulation or ghost billet is
active.

Configuring special utilities is project specific (dampers, guides).

The control of the looper utilities (pusher, guides, dampers etc.) is functionally implemented within LOC. The
timing of the activation of these utilities is independent from the activation / deactivation of the controller.

LOC must implement calculations with the current values for roll diameter and gear ratio of the stand it is
currently operating with (taking any dummy stands into account). The drive dynamics are assumed to be
identical (otherwise a re-optimization of LOC would be necessary for each drive).

Deliberate over or under speeds during threading in the mill area of the loop controllers, in order to achieve
an improved thread response (dependent upon the mill circumstances), can be defined. This functionality is
a component of the function Adaptation and Feed Through Logic (SLI).

Following diagram shows PI Controller Block diagram for Loop control and Program Sequecncing

5.2.5.2.2
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5.2.5.1.8 The following typical arrengemnt shows loop control controller

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5.2.5.1.9 Loop Decrease Signal


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The module LOCLOGSW utilizes the available information from the


billet tracking. Each module in LOC is allocated to a stand in the billet tracking. The
modules LOCLOGSW must also be assigned to stands, that are not directly acting upon a
and shall be prosecuted.

loop, but could form a loop, if a stand is not selected (in practice, this always causes more
LOCLOGSW modules to be set-up, than there are loop controllers).
The interfaces "Summation of the Run
Times from the Reference Trace point" and "Reference Trace point Loaded" should be
adapted by the design or commissioning engineer to the worst case occurrence, during
loop decrease (largest loop / fastest material speed to be expected). This adaptation
signifies that the design or commissioning engineer defines a reference trace point for
each LOCLOGSW module and utilizes the sum of the run times from this reference trace
point to each LOCLOGSW module.
The LOCLOGSW module generates the difference from the sum of the run
times from this reference trace point and the "Decrease Time" and delays the signal
"Reference Trace point Loaded" by this time value and transmits it as the signal
"Decrease" to the corresponding LOC. If the corresponding drive is not selected, then the
signal is transferred to the next selected upstream drive via the inline interconnected
LOCLOGSW modules. Configuring should take into account the correct calculation
sequencing (downstream), since the decrease signals must be fed through faster than the
decrease times. An error message output occurs for implausible times (is also transferred
to LOC).
The block transfers the signals between the LOC_KERNEL blocks just
in time in direction upstream and it creates the switching logic for the
LOC. For the transfers of the signals between the LOC_KERNEL
blocks it is like an interface block.

Pusher Displacement
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The activation of the looper


utilities (pusher, guides, dampers, etc.) is implemented functionally in
LOC. In principle, the activation of the guides and dampers are project
specific.
The module for activating the solenoid valve for the pusher can be
taken from the I&S TC library. Any possible manual operation of the
pusher must be implemented within the framework of the I&S TC
module as project specific. The automatic operation is supported by the
signal "PUSH_OUT" from the LOC logic (LOCLOGSW) in the manner
described below.
PUSH_OUT:
The points in time when deflection (loop increase) and retraction (loop
decrease) of the pusher take place, are influenced by the mechanical
design features and are not identical with the points in time for
activation and deactivation of the loop controller.

5.2.5.1.10 Deflecting the Pusher (Loop


Increase):

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The signal to deflect the pusher can be generated, at the earliest,


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simultaneously with the loop controller activation. This signal can also
be generated a little later via an activation delay. Project specific
coding will be required if an individual solution requires this signal
earlier.
and shall be prosecuted.

5.2.5.1.11 Retracting of Pusher (Loop Decrease):


The signal to retract the pusher can be activated via a correction time before (-) or after
(+) the loop decrease signal.

5.2.5.1.12 Special attention must be paid during the configuring and commissioning
that the correction time for retracting the pusher is smaller than the run time of the
material tail from the reference trace point to the loop decrease signal. This is valid only
for the size of the time value for negative correction times.

Setpoint Handling
Differing loop height setpoints are injected, dependent upon the material position. Immediately subsequent
to the material thread in, the current actual value can be optionally injected as the setpoint and the controller
enabled. The setpoint is then driven to the operating setpoint via a ramp. Switching then occurs to the exit
setpoint at the correct time before the billet exits, such that the loop can be decreased before material exit.

The operating setpoint is defined via the HMI, the exit setpoint is set as a constant one time only during the
commissioning phase.
Differing loop height setpoints are entered, dependent upon the material.
The set-up occurs via the HMI. It is dependent upon material, the loop geometry and the current velocity. It
should be noted that excessively high values of loop height could lead to mechanical instability and
insufficient loop heights and controller stability problems.
Loop height setpoints are converted to loop length setpoints before comparison with the actual values.
Adaptation (Optimization)
A signal is transmitted to the module SLI, if the loop controller detects an optimal speed relationship
between the two participating drives, following thread in.
Loop Increase
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Differing utility devices are available to support the loop increase, or to make it, at all possible in the first
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place.
- Loop Pusher
Pushers are used to support the loop increase for stationary or off center loops.
The activation of the loop pusher occurs via separate modules. FB_YR2 is used for Loop pusher activation.
The pusher may only actively participate in the operation when the material has safely threaded into both
corresponding stands. The time response of the pusher is determined during the commissioning phase and
is integrated into the control response of the sequence control.

- Dampers

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Dampers ensure that, for hanging loops, the material is initially threaded into the following stand. The
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dampers are lowered after the material has threaded into the next stand to allow the material to hang
through.
The activation of the dampers is project specific.
- Guides
Non-fixed guides are installed to help thread the material into the next stand with off center running loops.
These guides can also be retracted when the material has threaded into the next stand. The loop is
and shall be prosecuted.

extended with the support of a pusher after the guides have been retracted. The time response of the
guides is determined during the commissioning phase and is integrated into the control response of the
sequence control.
The activation of the guides is implemented project specific.
Switching Logic to Activate / Deactivate the Loop Controller
The enabling or disabling of individual controllers, and the timely output of supplementary setpoints and
optimization values are derived from the mill configuration data contained in the pass schedule (selected
drives and controllers), the mill usage (material tracking) and other, partially plant specific enable signals
(i.e. during chopping).
Switching Logic Loop Increase For this logic ref LOCLOGSW Block
LOC Specific Sub-Functions and Function Blocks
The LOC consists of a group of functions, which are distributed to various function blocks.

Functions in the Controller Section


The function LOC Controller Section is a sub-function of the function block LOC_KERN and is described
here for clarity as if it were a separate function.
The controller function is implemented via a PI controller block. This guarantees a stable reaction to
disturbances and permanent control deviations are prevented. The controller block also contains control and
limiting mechanisms. Therefore the output of the controller (speed supplementary setpoint) can be limited.
In addition, control inputs are available for selecting the mode of operation and for enabling / disabling the
controller.

Limiting values: 5% of the maximum speed (default).

- Functions in the Setpoint Channel:


A switch is made from the operating setpoint to the exit setpoint with the aid of a multiplexer and is
dependent upon the material position.
The selected setpoint is subsequently injected via a ramp function generator (ramp). The interface
SET_R_VA permits selection of whether the ramp function generator initiates from the current setpoint or
the current actual value. The input SV of the ramp function generator is supplied with the current scaled loop
height actual value.

- Functions in the Actual Value Channel:


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The loop height actual value is recorded from the loop position encoder via the separate function "Read
Analog Input". This function converts the value received from the loop scanner, via the analog input module,
into real format. The scaling of this value to the rated range of the loop height is implemented in the kernel
block.
Subsequently, the conversion of the loop height into the equivalent loop length is implemented via the
function "Conversion Loop Height into Length" (see the following).

- Formation of the Displacement Variable:


The control deviation is determined in the integrated PI control block. The KP factor of the controller block is
adapted via the function "Adapt Scaling Function" (see the following).
The integrated PI controller calculates the output displacement variable from the current control deviation.
Subsequently, the function "Loop Monitor" (see the following) is checked, whether the control deviation lies
within a predefined tolerance bandwidth for a certain time period.

Function Loop Height into Loop Length Conversion


This function is a sub-function of the function block LOC_KERN. The function is described here, for clarity
as if it were a separate function.
This is a principle description, since the function is utilized in multiple places (for actual value, setpoint and
maximum value).
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The function calculates the loop length SV as a function of the loop height SH.
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The loop length is a dimension for the amount of material, stored in the stable loop. It is calculated as the
difference between the material length held between the guide rolls for a stable and a stretched loop.
and shall be prosecuted.

If the stand layout is assumed to be as the above diagram, then the loop length can be approximated with
small loop heights according to the following formula:

All variables are specified in the units [m].


The reverse functions to test:
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Function "Adapting the Scaling Factor"


This function is a sub-function of the function block LOC_KERN and is described here for clarity as if it were
a separate function.

The input and output variables of the controller are scaled to rated variables. The KP of the controller is
optimized to these scaled settings. When these rated variables are modified, then KP must also be adapted.
The rated loop height will not however change, since it is allocated to a predefined controller. Changes can,
however occur in the gear ratio and roll diameter (both at the next possible stand and also other stands
when stands are not selected).
The gear ratio and the roll diameter are integrated into a so-called speed / velocity factor SVF. This factor is
defined as follows (original definition is in the module REF, and is only reproduced here).

Excerpt from REF:


This factor is determined from the gear ratio and the working roll diameter. The speed of the drive is
multiplied with this factor to achieve the output velocity of the material.

Definition speed velocity factor refer REF_KERN

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The adaptation of the internal KP factor results from:


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KP internal = KP * SVF_NOM / SVF_OP


The optimization of the loop controller requires the acceptance of the value from SVF_OP that is to be set at
SVF_NOM.

Function "Calculate Loop Decrease Time"


and shall be prosecuted.

This function calculates the loop decrease time of the corresponding loop control, dependent upon the
currently defined loop length setpoints and the set slope of the setpoint actuator (ramp function generator)
for reducing the loop.
The delay DECR_DEL is dependent upon the cycle and dead times present in the control loop and must be
determined and set during the commissioning phase.

Function "Loop Monitor"


This function is a sub-function of the function block LOC_KERN.
Looper Calibration
For loop scanner has analog signal for loop control and digital signal of loop scanner is used for tracking
We can do all looper calibration from HMI, looper calibration is carried out by using Radiant Bar, and there is
some calibration procedure for loop scanner, connection diagram is shown below
Connect multi meter across blue & yellow wire as shown in fig to measured mA ,Keep radiant bar on
Looper table below the loop scanner in such way that for zero loop height multi meter show 4mA.
Moving source up to getting 20mA in multi meter and mark maximum loop height at 20mA.and fixed loop
scanner at that position. Then moving source in between mark point, multi meter should vary continuously
from 0 to 20 mA. In this way we can calibrate loop scanner.
As shown below details connection diagram for loop Scanner,
Black 1 & Black 2 connect 230v supply to scanner
Black 4 & black 5 for Test output
Blue & Yellow for analog signal.

Loop scanner calibration can be done from HMI screen as shown. Ref following diag.
Current Point1- This is first measuring point for current. At this point measure 4mA for zero
loops Height. Adjust 4mA and press cal point1 for caliber first point
Height Point1- This is measuring point for minimum height, this point is used for measuring
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Minimum loop height, at this point loop height should be zero for 4mA.
Current Point2- This is second measuring point for current. At this point measured 20mA for
Maximum loop height and press cal point2. adjust 20mA and press cal point for
Caliber second point
Height Point2- This is second measuring point for maximum height which is used for measured
Maximum loop height, at this point measured 20 mA for maximum Loop height.

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The following block shows how to set 4-20mA in block and Anglog signal and also shows looper calibration
block.
A_IN block is used to connect anlog signal from Scanner which convert count value in mA depanding upon
setting In Y output this is connected to LOC_AI V_VOLT this block is calculate loop height depanding upon
calibration
For calibration CAL_SCAN block is used this directly conncted to HMI

This one is placed on STD 14,STD 15,STD 16 and NTM A , B chart on page D
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5.2.5.1.13 5.2.5.1.8 Area controls and functions


There is one chart for each area of the plant to control all the group and area functions.
CTR_RM_CO_GEN, CTR_IM_CO_GEN, CTR_FM_CO_GEN

The functions are:

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CTR_RM_CO_GEN
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General functions are:


- subordinarted visualization
- entry enable
- general operation modes
- general evaluations
- general CSM functions
and shall be prosecuted.

- HMI Interface to the mode selection and switching (B1)


Description of VISU_GENERAL*********************************************************************

*********************************************************************************************************

- Check for entry enable for this area (C1)


for engineering, connect all drives to the MATIN block, connect all auxiliaries, which have to
be in homeposition before the head of the material arrives, to HOME_POS
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- Schedule active set/reset (C2) for engineering check that all drives and auxiliaries of this
area are connected
- Area/group diagnosis (C3)
- Mode switching mainly by block OPM_KERN and local selection (D1)
for engineering check that all drives and auxiliaries of this area are connected

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Description of OPM_KERN***************************************************************************
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*********************************************************************************************************
- Area start/stop mainly by block SDV_KERN (D2) for engineering check that all drives and
auxiliaries of this area are connected to the outputs of SDV_KERN
- Shear command handling from Pulpit to SHE (D3)
- Cascade command handling for the area (E1) for engineering check that all drives of this
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area are connected


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- Check for upper / lower speed limit for manual cascade and technological cascade. If one
drive in the mill reaches the limit, no more cascade adjustments will be allowed to all of the
drives. (E2) for engineering check that all drives of this area are connected
- Generating of area empty signal, for engineering check that all HMD, Loop scanner of this
area and the last one of the area before and the first one of the next area are connected to
create the signal. (E3)
- Calculating of stopping time. During a fast stop the target for all drives in the area is to
reach zero speed at the same time. Therefore all stopping times of the drives are collected
and the maximum time is send back to the drives. With this time (ramp) all drives will brake
during fast stop. (E3) ) for engineering check that all drives of this area are connected
- CSM switching status display. (F1) for engineering check that all drives and auxiliaries of
this area are connected

5.2.5.1.14 5.2.5.1.9 Cascade Control

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Cascade control is provided to enable the operator to react to conditions in the mill which require speed
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corrections or change of speed relations or speed up the entire mill by selecting the leading stand. Cascade
control is applied to all drives that are in contact with the actual rolled material.
After selecting the desired stand with a stand identification key, the speed can be adjusted (increase or
decrease) with the help of the Follow-up twist switch.
The following adjustment velocities are recommended:
++ = higher speed quickly (1 %/sec)
and shall be prosecuted.

+ = Higher speed slowly (0,3 %/sec)


0 = stop adjustment
- = lower slowly (0,3 %/sec)
-- = lower quickly (1 %/sec)
Upon actuation of the twist switch the speed reference values are continuously increased resp. lowered for
the selected stand drive including all stands positioned from selected stand towards furnace. The speed
ratios between each two stands actually included into the cascade remain unchanged during manual
adjustment. If the master stand is selected the speed level of the complete mill will be adjusted.
The cascade adjustment is only possible in automatic operating mode.

There are a few blocks responsible for the cascade control.


- First of all the cascade selection block REF_DISTR in the chart GENXX. This block is
responsible to distribute the signals from the main pulpit to the processing blocks in the
different STDXX charts.
.
*********************************************************************************************************

*********************************************************************************************************
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- The block REF_STANDSEL in the chart STDXX is responsible for switching through the
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cascade selection signal and defining the stand which is selected. Important is that the loop
need to be closed. This means the output ESS of the last stand of the line need to be
connected to the input EOS of the first stand in the line. All blocks need to be in one
sequence starting with the first stand, so that a rising edge for a selection signal can be
received within one cycle from all blocks. Otherwise the selection is not working. Special
attention need to be given in case the cascade need to be split over two CPU. A special
arrangement need to be done at this time (done in Wuhan WRM project).

*********************************************************************************************************

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*********************************************************************************************************

- The block REF in the chart STDXX is doing the rest. He is handling the speed changes on
the selected stand and on all upstream stands.
Important for the manual cascade changes are these in-/outputs:
CCD (mode cascade selected), SGL (mode single selected), STS (this stand for manual
cascade selected), CPP (cascade plus plus adjustment), C_P (cascade plus adjustment),
C_M (cascade minus adjustment), CMM (cascade minus minus adjustment), SFF (speed
adaption from following drive) and all V_I_XXXX inputs, which are used to shift through the
data from the selected stand to the cascade visualisation block, SFD (speed following drive)
STP (speed adaption to previous REF block)

If the stand is selected, then the output STP will change by moving the Follow-up twist
switch. This value will be transferred to the next upstream REF block und in combination with
the speed relation the speed change for this drive will be calculated and will be given to the
drive and the value will be send by the output STP to the next upstream stand.
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For engineering, check that to all inputs there are the right signals connected, that the line from STP of the
last stand to SFF of the first stand is complete, that the line of V_I_XXXX inputs of the first stand to the
cascade visu block VISU_CASC is complete and that the loop of REF_STANDSEL blocks is closed. If this is
fulfilled then the cascade is working 100%.
If you need to uncouple two areas, because there is a long rollertable in between this two areas, please
disconnect input SFF from the last stand of the first area. With this the speed changes coming from
downstream will not be send to upstream any more. The speed relation between the stands will change.
Also remember that you probably need to design two cascade controls. This means there need to be two
closed loops for the REF_STDSEL and two set of devices on the main pulpit.

5.2.5.1.13 Self-adapting System


A control with self-adapting behaviour is integrated in the control system. The purpose is to assist the
operator by partly transferring his empirical learning behaviour into the automation system.
The system acquires the actual parameters of the technological controls (MTC, LOOP),
evaluates them according to specific criteria, and makes them available to be output for the next billet.

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The setpoint adjustment is continuously provided with optimised values, leading to a rapid setting of the
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train.
The self adapting system is realized in the block SLI_KERN. This one is placed on each STDXX chart on
page E1.

Description of SLI_KERN*****************************************************************************
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*********************************************************************************************************

The block is responsible for the decision that the additional speed reference by the technology will be given
to the upstream stands if they are loaded with the same billet as this stand.
For engineering therefore it is most important that the inputs SUO (stand upstream occupied) and SDO
(stand downstream occupied) are connected in the right way. Take care that the tracking provides these
signals in the right sequence.

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For example for stand 4, connect to SUO the TP_OCCU of the tracepoint of stand 4 and to SDO the
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TP_OCCU of the tracepoint of stand 5. Careful if there would be a HMD tracepoint in between the stand 4
and 5 tracepoint. Dont connect this TP_OCCU to the SLI. Always and only use stand tracepoints.

If the billet is the same in this stand and the upstream stands, then the inputs IDF (intervention dynamic
following stand, during loop regulation) and ISF (intervention static following stand, taken over speed value
after regulation) will be set in relation to input SRL (speed relation factor) and be given to the upstream
and shall be prosecuted.

stand.

For engineering take care that the line IDP and ISP from the last stand to the inputs IDF and ISF of the first
stand is correct.
If you need to uncouple two areas, because there is a long rollertable in between this two areas, please
disconnect input IDF and ISF from the last stand of the first area.

The memory of the selflearning will be reset with the signal NSC (new schedule received)
This means if you want to save the learned speed values you need first to save back them from operation to
modification or to archive, and then based on this set a new schedule active.

With the signals, either LCO (loop control optimum) or MTO (MTC control optimum) the additional speed will
be saved and according to the preselected take over ratio TLC given to the drive.

Warning: Take care for LC_LE_FC (loop control lead factor). Normally this one is designed to preset a
adjustable percentage of tension for the time of loopforming. It should be a value between 0 and 1. Please
consider if you want to set 2% tension you have to calculate it like following: 2% = 0.02 and then multiply
with TLC (normally 50% = 0.5). The result would be 0.01.

5.2.5.1.14 Spindle Positioning


For changing the stands of the mill the wobblers of the various drives should reach a predetermined
position. The position control system detects the difference between the setpoint and the actual position of
the wobbler and turns the motor to the desired position . The roll changing position of the spindles of each
stand can be indicated on the operator terminal.

There are two ways of doing the positioning. One way is expensive and quite accurate, the other is cheap
and not too accurate.
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For the first one, the drive system has to take over the positioning task, therefore a additional technological
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card is necessary. The basic automatisation only sends the request signal to the drivesystem, the drive
system is positioning and sends back the feedback in position.
This kind of positioning is not included in the program and can be represented by the block FB1057.

For the second one the positioning is done by the basic automation. On request the basic starts turning the
drive with a preset slow speed. The right position is detected by a proximity switch. After first detection, the
speed will be reduced and with the next detection the drive will be stopped. This kind of positioning is
included in the program and represented by the block FB1056.
This one is placed on each STDXX chart on page F4.

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5.2.5.1.15 Rolling Mill Simulation


The rolling mill simulation makes it possible to attempt a rolling operation without material charge. When it
runs before starting a new rolling program or after a downtime the mill can be checked without material
and shall be prosecuted.

losses or equipment damages.


The rolling mill simulation runs only in automation mode. With the command SIMULATION ON given by the
operator via HMI, the simulation function sends test signals to the HMDs and loop scanners of the mill train
to simulate the movement of a virtual bar being rolled according to the actual mill speed. The virtual material
passes the mill train and switches the technological functions on and off depending on its position. These
procedures can be observed on the HMI sceens.
All the automatic speed corrections are blocked during this test sequence. The proper function of the hot
metal detectors, the loop scanners, the pushers and the shears is tested.

By selecting SIMULATION on HMI for an area and then pressing START/STOP there will be
a endless billet started in the Intermediate and Finishing Mill or continuously coming/going billets for the
Roughing Mill.
The time for billet run and gap time can be adjusted in the program in chart SEQRM on page B1.

*********************************************************************************************************
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*********************************************************************************************************

If simulation is selected in more than one area in a row, the simulation only need to be started in the first
area and will automatically continue into the next one.
The program is written in that way that in case of prevent next billet signal, the simulation in Roughing Mill
will be stopped until the problem leading to the fault is solved. This should teach the customer from the
beginning to have a look on the prevent next billet signal and not to roll by ignoring it.

If simulation is selected in the overview picture, then all areas displayed there will be in simulation mode and
with starting the simulation, continuously coming/going billets will be send into the mill.

5.2.5.1.16 Diagnosis system


Theres a small logic included to better diagnose a fault in the mill.
The block which is doing this is placed in each STDXX on page B5 and GENXX chart on page C3.

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and shall be prosecuted.

There are 16 inputs which can be masked and therefore are only displayed or disable the drive from
running.
For example if a proximity switch detects a fault, this fault will lead to the stop of the drive.
But if it was only a short fliggering, then you need to search the messages for the reason.
With this system the fault will be remembered and therefore easily visible to the user.
On his acknowledgement or if the drive will be restarted, the gone fault will be reset.
The block is designed that any time a unused input can be connected and the on hmi displayed text can be
written on the block, without need for a new mapping.

Normally there is one diagnosis block for one area in the CTR, one for each drive in the CTR and one or
more for all the signals in the MIL.
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5.2.5.1.17 Auxiliary charts


There are some charts which provide the main charts with inputs and informations.

1. CTR_CO_GEN chart
and shall be prosecuted.

Here General Functions like below are handled:-

- Mill Emtpy

- Entry Conditions Enable

- New Schedule after restart

- Home Position

- Prevent Billet

Here the fault interconnection to the MIL CPU will be handled. Therefore the block MILL_STOP was placed
on page B1.
*********************************************************************************************************
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*********************************************************************************************************
All 60 or 300 sec faults for each area will be received and according to the mill situation (empty, billet inside)
the corresponding area will be stopped immediately or a shutdown timer will be started and the mill will be
stopped latest after 60 or 300 sec.
This is done by the block SHUTDOWN, placed on B2.
*********************************************************************************************************

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*********************************************************************************************************
Another main part of the program and this chart is the block PREV_BIL, placed on C1, which collects all
signals of all areas which lead to the status prevent next billet. Basically its just a big internal OR.

*********************************************************************************************************
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*********************************************************************************************************

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For engineering, just connect the signals and areas for your mill and disconnect the ones not necessary.
With the input ENB_ROLL (as button available on HMI) you can deactivate the prevent billet control. Rolling
would be possible, but probably lead to a chopping depending which part is not ready.
If you need to roll for example in roughing mill and intermediate mill, while finishing mill isnt ready yet, then
set input ENB_FM to 0, which means this area doesnt count for the prevent next billet signal any more. But
dont forget to block the automatic scraping release for RM shear and IM shear, they surely would start
and shall be prosecuted.

chopping when the cut HMD detect material if you try rolling and an area is not ready.

2. CTR_CO_INIT chart

Here some system data and functions are placed and realised.
This CFC includes the system functions for
- restart
- cyclic program
- flashing flags
- HW error handling
- SW error handling

On page B functions for initialising, scanning time, OB time measuring, OB begin and end definition.
For engineering nothing need to be done.
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On page C there are placed some counter for OB faults. No special need any more. Before
the blocks OB_BEGIN and OB_END where included in the program, it was necessary for each OB which
the program liked to use, to install at least one block in the rungroup.

Finally on page D there are the terminal blocks for the profibus addresses.

For engineereing check these with the hardware setup and adjust them according to the mill. Carefully,
every address need to be used only once.

3. CTR_CO_GEN_VISU chart

On this chart the HMI interface and messages for the cascade control have been realised.
The block VISU_CASC handles the display auf the selected stand during manual cascade changes.

*********************************************************************************************************
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*********************************************************************************************************

For engineering take care that the last stand of the line is connected to this visu block.
If you have two uncoupled cascades (for example because of a long roller table between two areas) then
you need also two of this VISU_CASC blocks.

5. SELECT chart

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On this chart some selections and releases are done.


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For example the release for external windows of all sequencer areas are done central from page B1. For
engineering take care all EXT_WIN inputs of all the Hardware trigger tracepoints are connected to here.

The switching of the drives into profibus simulation or not are done on the pages C. For engineering take
care all drives of the mill are set up here. Before you go on site simulation is always 1, after you are on site
and shall be prosecuted.

simulation always has to be 0.

On page C5 theres a test for cobble detection prepared. Use this to test the cobble detection in the mill
during simulation.

On the pages D1 and 2 theres placed the release for PDA. This is quite important. If theres no PDA
available or the PDA connection is disturbed for some reason, then disable it.
Otherwise its possible that the CPU goes to stop. If you plan to switch off PDA always disable it here before
you switch off.
For engineering connect all the profibus addresses used for the PDA to the block PDA_ENB.
In case theres a fault the system then tries to switch off the runtime groups of the PDA program.
Unfortunately this in some cases is not fast enough.

Finally there is the central release for the communication to other CPU. Release only the communications
which are physically established.

6. EX_STD chart

The function of this chart has to be seen as interface to other CPU. The basis is the block
EXIT_STAND.

Description of EXIT_STAND*************************************************************************
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*********************************************************************************************************

For engineering take care that all stands of the mill are inside and connected. The chart is
especially useful if another program part need to know the speed of the last stand before the finishing mill
and this last stand can vary in the mill. In this case the block is shifting the exit speed according to the
selection of the stands.
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The block for the last stand normally also provides stand and speed information to the COL CPU the one of
the finishing block to the WLH.
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7. CTR_CO_COM_PDA chart
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In this chart the signals from the program to the PDA system are connected. Most important and common
useful signals are already preconnected.
For engineering connect additional signals to the spare inputs.
There are two kind of blocks used for the communication. One for 16 binary signals and one block for 16
analog inputs.
and shall be prosecuted.

There are 32 binary and 32 analog inputs each channel and 8 channel (profibus address 80-87) available in
the standard CTR.
Following DBs need to be added as per structure given below:-

*********************************************************************************************************
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Communication is over Profibus using the standard DP send and receive blocks.

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Below are the simple Boolean to Word blocks which convert Boolean signals required on IBA into REAL (32
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bool signals = 1 Real signal)

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*********************************************************************************************************

For engineering there is a parameter FACT_XX. This one is adjustable from 0.01 to 100.
A setting of 10 would mean the value at the corresponding input will be multiplied with 10
and the send to the PDA system. The PDA divides the value by 10 to reach the original value. Sure
therefore on PDA side the necessary parameterisation need to be done.

8. CTR_CO_COM_COL_D chart

This chart has to be seen as interface chart to the COL CPU.


For engineering first of all check the exchanged signals. The more important thing is the program which
generates the signal hold speed. This signal is important for the pinchroll and shears after the last stand, to

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keep going and remove the material in case of a cobble and in case the last stand would be stopped.
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In normal mills several stands can be the last one for different sizes, so that a multiplexing for the generating
of the freeze signal need to be done. As point to start freezing always use the hardware tracepoint in front of
the last stand.

9. CTR_CO_COM_MIL_D chart
and shall be prosecuted.

This chart has to be seen as interface chart to the MIL CPU. On the B pages there are signals for all stands
coming from MIL and going to the CTR process.

O_ENB (operation enable), needs to be 1 for starting, dont necessarily leads to a stop if it goes 0 during
running)
R_ENB (reference enable), needs to be 1 during start and running, a 0 leads to immediately stop
RECT_OK (rectifier running) needs to be 1 to enable running of the drive
JOG_FW (jogging forward) together with mode local makes drive turning forward with preset jogging
forward speed
JOG_BW (jogging backward) together with mode local makes drive turning backward with preset jogging
backward speed (attention some finishing blocks are not allowed to turn backward, block it by
disconnecting)
For engineering take care all drives are interconnected by this terminal blocks from MIL to CTR. A easy
centralized simulation off this signal is possible in this way.

Additionally theres a small logic for the pinchroll in front of the first stand for automatic open and closing.

The automatic cooling water control is done by the block COOL_WAT.

*********************************************************************************************************
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*********************************************************************************************************

For engineering take care all actual speeds (NAC) and maximum speeds (NUL) of all drives
are connected to here. With the setting at PERC_1 you can set the speed percentage limit the water should
be turned on in the roughing mill. (PERC_2 = intermediate, PERC_3 = finishing, PERC_4 = finishing blocks)

10. SNAP Shear

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Snap is used for blocking material of flow during abonormal condition occurred in mill.In bar mill there are
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total 5 snap shear & one toggle shear before stand 1, toggle shear operation is manual operation and sanp
shear before std 14,std 15 and std 16 also manual operation ,From main Pulpit (CP2) we can close all Snap
Shear, but allow opening of all snap shear from OS only. In chart showing open/close logic
for all snap shear and toggle shear. Logic for all shear is same.
and shall be prosecuted.

5.2.5.2 SHE: Technological Functions


Since latest version PCS7 V6.1 is former SHE-CPU program included in CTR-CPU.
Charts COM, COMGD, SELECT, SYSTEM of SHE-CPU and CTR-CPU are combined to only one chart.

According to Charts:

COM PDA_SHE SELECT POWER SLITTER


SHXXAUX SHXXMAIN SHXXVMES SYSTEM
CHWRMAINNTM_A CHWRMAINNTM_B
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5.2.5.2.1 Shear main functions

First of all the shear consists of the similar structure like a rollertable. It includes VISU and terminal blocks to
provide the necessary inputs, it includes the drive switching SDV block, the speed generating block REF
and the drive communication block special for shears FB_SHE.
One difference are the two diagnosis blocks, one for drive conditions, one for scrapping conditions.
In principle the basic function of FB_SHE is similar the SIN_MDV.

For the shear cutting there are additional blocks working.

Following blocks are all involved directly or indirectly into the cutting process.

Please dont change the input and/or output addresses which are used. Keep all the addresses from the
standard project otherwise its possible that some functions are not working properly any more.

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Please consider a change of the alarm OB number and/or the alarm interrupt number forces you to restart
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your CPU, otherwise this change is not becoming active.

Normally the only things which need to be done for the shear part are:
- adjust shear auxiliary program (switches, scrap boxes, flaps)
- adjust scrapping logic to mill requirement
- adjust shear parameters (via HMI picture in maintenance area)
and shall be prosecuted.

All the functions for the shear cut itself are already connected and working.

Description of OSI_KERN*************************************************************************
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*********************************************************************************************************

For engineering dont touch, dont change, all connections are already done. The only important thing is
that for each OB20-23 which is used there needs to be one of this blocks parameterized with the OB
number.

Description of OSI_REQ******************************************************************************

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*********************************************************************************************************

For engineering dont touch, dont change, all connections are already done. In a normal project the first
shear (Roughing) gets OB20 INT_NR 1, the second shear (Intermediate) gets OB20 INT_NR 2. (If there
would be a third shear it would be OB20 INT_NR 3. If there would be more than 4 shears to handle it would
be necessary to insert one more block OSI_KERN and use OB21. In this case another 4 interrupts would be
available.
This block receives its inputs from the SHE_SEQ block and is responsible to trigger the internal OB20
interrupt alarm in time.

Description of OSI_ALARM*************************************************************************
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*********************************************************************************************************

For engineering dont touch, dont change, all connections are already done.
This block outputs the alarm as soon as the alarm time is counted down. Normally with this OB20 interrupt
cut handling, a accuracy of 1ms can be achieved.

Description of OSI_SET******************************************************************************

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*********************************************************************************************************

The output AL_OUT of this block will trigger the hardware signal to the shear to start the cut.
Every time there is a high edge at the input CYCL_SET (useful for manual cuts) there will be a cut request
signal send to the shear.

Description of SHE SEQ*************************************************************************


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and shall be prosecuted.

*********************************************************************************************************

This block is used for tracking the head and tail of the billet. According to the position the time for the cut
command will be calculated and the cut will be started. For engineering there needs to be done nothing for
this block, all interconnections are already done.

Description of SHE_CUT*****************************************************************************

*********************************************************************************************************

Description of SHE_SET*****************************************************************************
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*********************************************************************************************************

For scrapping control of the shear following block is used:

Description of SHE SCRAP*************************************************************************

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*********************************************************************************************************

Basically there are two kind of chopping, automatic and manual. The difference between both is that manual
chopping can be stopped by the input CHOP_OFF any time, while a automatic chopping can only be
stopped if there is no material in front of the shear. (Input NO_MAT). For engineering connect all manual
chopping reasons to the input CHOP_MAN and all automatic chopping reasons to the inputs CHOPPLC1-5.
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Shear auxiliary functions


In this chart auxiliary functions like deflector switches, scrap boxes, flywheels can be placed. For
engineering they are project specific to program. Follow the programmed typicals and use block FB_YR2 for
valve controls.
and shall be prosecuted.

Important for the process is the signal SHX_AUX_HOM_POS generated by the block SHXADD.

For engineering you can combine this signal with the project specific auxiliaries. For example with a
deflector switch which need to be retracted for normal rolling operation.
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5.2.5.2.2 Shear speed measuring function


In this chart a typical for speed measuring has been set up. In a real mill the speed of the material is always
slightly higher than the speed of the driving stand. (aprox. 1-3%, in special cases it can also be up to 8%) .
For an accurate cut during high speed rolling, the real speed need to be measured and taken into
and shall be prosecuted.

consideration for the shear cut timing.


Normally this is not necessary in the low speed areas besides there is often no space to put two HMD in a
row before these shears. It makes more sense for the shear in front of the finishing blocks, because speed
and distance are bigger there.
Its essential to measure the speed for the dividing shear in a bar mill, its nice to have for a
shear in front of the finishing block in a wire rod mill.

The speed measurement is done by the block VMES_CALC placed on C1.

Description of VMES_CALC*************************************************************************
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*********************************************************************************************************

The block VMES_RT assists by calculating the 1ms exact runtime between two hardware trigger, in this
case two HMD signals.

Description of VMES_RT*****************************************************************************

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******
***************************************************************************************************

For engineering, there is nothing to do for the measuring system. Only the decision to use or not to use it
needs to be done, depending on the mill situation.
If not used, be careful, then the calculated speeds on C2 connected to the SHESEQ block for head and tail
speed need to come directly from the CTR communication (connected to B1 block VISUVMES input
XVMSA_H and X_VMSA_T), a reconnection is necessary.
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5.2.5.2.3 Auxiliary charts

1. System see CTR SYSTEM,


and shall be prosecuted.

additional there is the basic parameterization for the shear cutting function included

First of all the block OSI_KERN on C1. Its used to define the Alarm OB. Its possible to us Alarm OB
20 to 23 in the program. For each OB there can be used maximum four interrupts. This means
maximum 16 interrupts per CPU for alarm triggered actions like shear cuts..

Second OSI_ALARM on C2.

Also reading the periphery bytes and then transferring the single bits to the process the same as
writing the bits to the periphery word is done in this chart.
Attention, this blocks run in OB40, this means as soon as an hardware interrupt is received, OB 40
will be called and the bits will be set. Normally they are reset after the OB40 cycle and wait for a
new interrupt, in certain situations it can happen that they are not reset, this means a interrupt will
not be recognized. Only with the next interrupt, the the old and new one will be recognized. To
prevend this insert a small XOR block and read the inputword and write it to the same input word.

2. Communication see CTR COM

3. PDA see CTR PDA

4. SELECT see CTR SELECT

2. Chooping Shear
The program for the chopping shear is written in the
COL_CH_SHR1 chart AND Drive interfacing related logic is written in COL_CH_SHR1_DRV. This
shear is a simple speed controlled drive which is continuously run at a constant setpoint coming
from the pass schedule. There are mainly three blocks interconnected to switch modes SDV_KERN
(setpoint enable devices), handle the speed setting REF_AUX_DR (setpoint selection, quickstop
handling) and communicate to the drives through DRV_SND and DRV_RCV blocks with DRV_SIN
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(Sinamics drive communication). They are placed in the COL_CH_SHR1_DRV chart on page E. For
description, refer to the section on auxiliary drives operation.

5.2.6 COL
5.2.6.1 Bar Exit Section :
The bar exit section area comprises of dividing shear, cooling bed, cold shear,bar forming and removing,
bar bundling, counting, unloading.

5.2.6.2.3 Dividing shear


The speed setpoint of the cooling bed shear is dependent on the speed setpoint of the exit stand and the
entered speed lead factor.
The start signal for the shear cycle is calculated and initiated on the basis of the actual material speed and
the preselected cut length.

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After the cut the shear is returned to its starting position by automatic position control as part of the shear
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regulation.

5.2.6.3 Cut length strategy


The control is based on an estimation of the remaining length of material, contained in the continuous mill at
an early stage of the rolling of a billet. Via the estimated value a redistribution process for the last 2 or 3 bars
and shall be prosecuted.

is started to adapt a normal dividing length, down to a minimum length, in order to obtain a rest end which
exceeds a defined minimum rest end length. The minimum cut length is limited by factors like material
speed, cooling bed cycle, arrangement of running up system etc.
The last length can be longer than the order cutting lengths of the concerned rolled billet.
The final cut length strategy has to be discussed in detail with the mechanical supplier and the enduser. For
the realisation of the design a more detailed description will be necessary.
In order to realize the above mentioned cut to length strategy all needed physical, mechanical and process
conditions have to be fulfilled.

5.2.6.4 Cooling bed length cutting


The bar leaving the last active stand is cut into cooling bed lengths with the cooling bed shear. The cutting
lengths can be preset manually (inputs).

5.2.6.5 Cooling Bed inlet roller table and magnetic brakes


The material will be transported to the entry side of the cooling bed and positioned there by magnetic
brakes.

5.2.6.6 Moving Rakes and Aligning Rollers


The rake-type grid takes over the bars from the run-up system resp. from the first fixed run-up tooth of the
rake-type grid and moves them towards delivery roller table with each further cycle and that means to the
bar finishing line. Depending on the cooling strategy, the teeth of the rake-type grid are occupied several
times (normally double assignment) or are even left empty (empty teeth caused by multiple rotations).
Depending on the cooling strategy contained in the rolling schedule the rake grid cycle is to be controlled. In
addition, further idle cycles, e. g. for charge separation or cooling bed clearing, can be requested.
Normally an aligning rolling table is integrated in the rake-type grid. There the possible imprecisions when
laying down bars in the run-up system are corrected. The roller table rotates with constant speed. The bars
are laid down on the roller table by the rake-type grid for one rake cycle and are run against a mechanical
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stopper while the rolling table continues to rotate.


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Upon request several aligning positions can be acquired via adequate transducers. When reaching a preset
position, the bars are lifted form the roller table by a lifting device and are thus slowed down. Due to the
constant roller table speed, the braking distance is reproducable and that is how identical bar positioning
points are produced. In the next rake grid cycle, the lifting device is lowered and the next bar resp. the next
bars is/are aligned.

5.2.6.7 Cooling Bed Exit


The cooling bed exist side is equipped with a step-by-step chain transfer a roller table. Control is provided to
achieve the proper layer formation and transfer in automatic mode. The chain transfer is moved step-by-
step in co-ordination with the cooling bed movements for bar discharching and, when a layer with the
desired number of bars is ready, it is placed on a roller table by means of a set of extraction trolleys. The
roller table is then activated to feed the facilities located downstream.

5.2.6.8 Cold Shear Cut


Control is provided for the mechanical shear to perform in automatic mode a cut-to-length of the layers of
bars coming from the cooling bed and their transfer to the bundling area.

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Upon detection of the arriving layer by a front-end sensor, the layer is stopped and the shear is activated in
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order to perform the head cropping and the cut-to-length (according to the lengths set by the operator) using
the wheeled stoppers on beam as a measuring mean. The layers obtained after the cut are separated using
the different sections of the roller table which conveys them to the bundling area.

5.2.6.9 Mechanical Bar Counter


and shall be prosecuted.

The material detecting sensor gives a signal when material is passing a specific position. The signals will be
counted and with reaching the set value the bundling is started.
Bundling Device
The bundling device is a stand-alone system delivered by the machine builder. When the bundle is
completed the basic automation system gives a command to the bundling device to start bundling. Is
bundling completed the bundling device gives a status signal to the basic automation system.

5.2.7 Program Structure


5.2.7.1 COL

5.2.7.1.1 COLTechnological Functions


According to Charts:

Charts similar to CTR charts (description refer to CTR program structure guidelines
COM HMDTEST L2DIAG PDA
SYS01 VISU
Charts special in COLSLOW CPU:
COL_CB_APRON BAR_CHT COL_GEN_DATSUP MEAS1A

COL_CB_MARKM COL_CB_CO_GEN COL_CB_RTAL COL_CB_RTINLxx


COL_SHE_SHEDIV BAR_CT DYCVIG COL_GEN_GALARM
COL_GEN_GCY36 COL_GEN_BARSIM COL_CB_SHPROL
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According to Functions:

5.2.7.1.2 Break Slide Switching (APRONS)


The program for the Break Slide control is written in the COL_CB_APRON & COL_CB_APRON_DRV chart.
and shall be prosecuted.

ThIs chart contains the following functions

Connections / Termination / Preset Data / for Tilting Aprons.

Visualisation / termination / Shedule data for Tilting Aprons.

Setpoint (SDV) / Refrence vaue(REF) / Drive Interface (DRV_SIN) logic for tilting aprons.

Logic for tilting Aprons auxilaryes operation & run enable conditions.
This chart has two important blocks:

CBARPCAL
ACT_POS

CBARPCAL :
The block contains the complete timing calculation and monitoring for the
moving cycle of the drive.
Mode of Operation : The block is called cyclic in a scan cycle.
All time calculations depending on the selected moving mode are included
and the times are present at the output values.
Depending on the type selection TAPTYPE different time calculations and
reactions are available. (For future. Up to now only one type possible =type 0)
Type 0: Tilting apron (e.g. Shijiazhuang/China)

TAIL BRAKING / LAYING POINT LOGIC

NO ROLLERS BETWEEN THE TYPE SEGMENTS


(IMMEDIATELY BRAKING AFTER MOVING TO DOWN POSITION)

START POS. = HOME POS. = UP


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LIFTING TIME IS VARIABLE (VELOCITY COMPENSATION)


Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

SLOW DOWN (OR STOP) DURING LIFTING POSSIBLE

MAGNETIC BRAKING POSSIBLE

MOVING WITH MOTOR DRIVE (EXCENDER, ONE DIRECTION


ONLY)

ACT_POS :

Brief Description : The block is for evaluation of an actual position value to


create cams, pulses, position windows etc. It can be used for circle and for
linear positions.
Mode of operation : The block is called in a cyclic scan cycle.
Enable of block functions : With the input signal ENPOS the internal
functions are enabled.
Position evaluation mode :The mode of position evaluation is switched with
the signal POSMOD. If POSMOD = 0 the block is for circular position mode

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(e.g. 0-360-0-360...). When the input signal is high (=1) the block is for linear mode (e.g. 2m to 3m).
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The scaling of the possible position range is done with the values SCALPOSL and SCALPOSU.
The value for position 0 ("start position") is equal with the lower position range limit SCALPOSL.
Range monitoring: For both modes (circular/linear) the range of the actual position is monitored.
If the actual position value from the drive / encoder is out of the setted range (SCALPOSL <-> SCALPOSU)
this output is setted to high.
and shall be prosecuted.

5.2.7.1.3 BAR_CHT(Sequence for Chain Transfer)


The program for the Chain Sequnse control is written in the BAR_CHT chart.
Introduction
The Chain transfer system is located on the discharge side of the cooling bed. The chain transfer
receives bars, one at each rake cycle from the cooling bed rake and collects bars in pockets located
on the chains. A collection of up to 28 pockets makes up a layer that will be transferred from the
chain transfer to the cooling bed run out table.
The transfer chain system is used to
Accept bars that are being dropped from the carryover rake.
Separate bars in pre selected numbers on the pockets in the chain. The chains have
pockets, which are 50.8 mm long during the length of the chain.
Sort the bars in layers of 2 to 28 pockets of which 28 are used for smallest sizes, making
layers ready to be transported to the cold shear run in roller table

5.2.7.1.4 COL_GEN_DATSUP
The program for the Data setup control is written in the DATSUP chart. This chart has two important blocks:

CBDATD1

CBDATPA1
CBDATAD1 :
Brief Description : The block is a central data handler. The distances etc. in
the COOL area are setted at this block and distributed from the output signals to
all other blocks which are using this values. All dimensions, distances etc. have
to be setted only once a time in the program.
Mode of operation : The block is active all the time and called in a slow cycle
scan time.
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Startup-functions : During system start the block is called for one cycle.
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CBDATPA1 :
Brief Description : The block is a central data handler. The distances etc. in
the COOL area are setted at this block and distributed from the output signals to
all other blocks which are using this values. All dimensions, distances etc. have
to be setted only once a time in the program.
Mode of operation : The block is active all the time and called in a slow cycle
scan time.
Startup-functions : During system start the block is called for one cycle.

5.2.7.1.5 MEAS1A
The program for the Mesurment System is written in the MEAS1A chart. This chart has two important
blocks:

MSIR

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CBMEAS1
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MSIR :

Brief Description : The block calculates the measuring velocity and the
difference between the reference exit velocity.
Also the impulse-valuation-factor of the exit stand will be calculated. This
and shall be prosecuted.

factor is the length of passed material trough the exit stand per one
impulse of the encoder of the exit stand.
If the difference between the measured values and between the
calculated values is too much (out of range), the reference values will be
used and a message will be generated.
Mode of operation : The block is called in a cyclic controlled scan area.
Only when the input ENCALC is high for one cycle (external cycle
impulse !) the calculations are done.
The trigger signal for this calculations is the signal RDILMS1A (" IMP+
READY IL-MEASURING LINE 1A") after the end of the measuring
calculation logic.
Startup-functions : During system start or after schedule change and
new bar behind last stand NSCHBARP measuring buffer ILVAL1
ILVAL3 is deleted. Also the correction factor for the measured velocity
CFAC is presetted with the value VCORE.
Entry data check : After ENCALC is activated the entry datas are checked before the new calculation wiil
start.
The output FM_ENTRY is setted if VEXIT<=0 or NEXIT<=0 or IMPEXIT<=0 or LGMES<=0 or VCOR<=0 or
VCORE<=0 or TCOUN<=0 or ICOUN<=0. Then the CFAC is setted with VCORE and the ILFAC is setted
with ILRD.
The output FM_VEXIT is setted if VEXIT<VMIN or VEXIT>VMAX. Then the CFAC is setted with VCORE.
The output FM_VMES is setted if (VMES<VEXIT*CVMIN) or (VMES>VEXIT*CVMAX). Then the value
VACT=VEXIT*VCOR.
The output FM_ILMES is setted if (ILMES<ILRD*CIMIN) or (ILMES> ILRD*CIMAX). Then ILRD is used for
the correction. The output FM_ILBUF is setted if ((ILVAL1+ILVAL2+ILVAL3)/3) = 0. Then the value ILFAC is
presetted with ILRD.
Enable of block functions : The functions are enabled after setting of the input signal ENCALC for one
cycle (cycle impulse !) and no error during entry data check (FM_ENTRY = 0).

CBMEAS1 :
Brief Description : The block is for measuring the bar velocity at the
head and at the tail of a billet between two fixed tracepoints (e.g. 2
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sensors).
Mode of operation : The block is called cyclic in a fast scan cycle.
Normally the fastest one.
Enable of block functions : The general enable signal for head
measuring is the input signal ENMS1AH and for the tail measuring
ENMS1AH.
Also the process signals ENIR and EXITON are needed to enable the
functions.
Measuring modes : The measured and actual valid value is available
at the output value VEXITCH (bar head measuring) and at the value
VEXITCT (bar tail measuring).
Depending on the input signal ENAV1AH and ENAV1AT the values
VEXITCH and VEXITCT are with or without averaging. If ENAV1AH /
ENAV1AT is active then the averaging with the last 3 measured values
(VEXITCH1 - VEXITCH1) is enabled.
As long as the measuring is active (passing time between the two tracepoints) the output signal ACHEAD1A
for head and the signal ACHEAD1A for the tail is active.
The start signal for head measuring (1st tracepoint) is connected to STAMS1H and the stop signal to
STOMS1H.
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The start signal for tail measuring (1st tracepoint) is connected to STAMS1T and the stop signal to
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STOMS1T.
Also the passing time for head (TMEASH) and tail (TMEAST) measuring is available.
Reset of block functions : The internal and the output datas are resetted after activating the input signal
RESET or during schedule change (NSCHDTP).
and shall be prosecuted.

5.2.7.1.6 COL_CB_MRAKM
The program for the Moving Rack System Master is written in the MARKMA chart. This chart has two
important blocks:

CBMRBAR
ACTPOS1

CBMRBAR :
Brief Description : The block is for tracking the bars on the cooling bed rake and for the take over position
into the bar handling area behind the
cooling bed.
Mode of operation : The block is called
cyclic in a scan cycle. Depending of the
number of entry positions, total rake cams
and the number of cams per rake cycle the
incoming bars from the braking system are
stored on each cam of the rake.
The total number of cams XRACKLE must
be be presetted. Also the number of cams
per cycle XNOTPCY.
With each rake cycle XRAKECY the
entered bars on the notches are moved.
For clearing the complete buffer the input
CLEAR is used.
The total numbers of bars which are
present on the rake are calculated and
available at the output value BARTOTAL.
Also when the complete rake is empty the
output EMPTYCBR is setted.
For the bar handling area the numbers of
bars in hand over position TAKEOVER are
calulated.
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ACTPOS1 :
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Brief Description : The block is for evaluation of an actual position


value to create cams, pulses, position windows etc. It can be used for
circle and for linear positions.
Mode of operation : The block is called in a cyclic scan cycle.
Enable of block functions : With the input signal ENPOS the internal
functions are enabled.
and shall be prosecuted.

Position evaluation mode : The mode of position evaluation is switched


with the signal POSMOD. If POSMOD = 0 the block is for circular
position mode (e.g. 0-360-0-360...). When the input signal is high
(=1) the block is for linear mode (e.g. 2m to 3m).
The scaling of the possible position range is done with the values
SCALPOSL and SCALPOSU.
The value for position 0 ("start position") is equal with the lower position
range limit SCALPOSL.
Range monitoring : For both modes (circular/linear) the range of the
actual position is monitoreIf the actual position value from the drive /
encoder is out of the setted range (SCALPOSL <-> SCALPOSU) this
output is setted to high.

5.2.7.1.7 COL_CB_CO_GEN
The program for the Cooling Bed Operating Mode Selection is written in
the COL_CB_CO_GEN chart. This chart contains the interface for data
from mill to CB area also all the operator interface commands transferd
to the program form this chart.
ThIs chart contains the following functions

Connections / Termination / Preset Data / for Operating Mode


System.

Visualisation for Operating Mode System.

Setpoint enable / start up / kernel / management / local pulpit logic for operating mode system.
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5.2.7.1.8 COL_CB_RTAL
Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

The program for the Aligning Roller is written in the COL_CB_RTAL chart

Introduction : For this mill and cooling bed arrangement, the tail ends positioned on the cooling bed rake
become the front ends leaving the cooling bed.
The carryover rake transfers the lengths of bar from notch to notch of the cooling bed stationary
racks. The notches are on 110 mm centers. At the last five notches at the discharge end of the
stationary racks, bars are supported in grooves of the aligning rollers. There are total of 60, 5-grooved
aligning rollers.

Description
The purpose of the cooling bed aligning rollers is to bring the front end of the lengths of bar into
alignment prior to discharge from the last stationary notch of the cooling bed onto the layer
transfer device. Such alignment of front ends saves time and reduces scrap at the cold bar
shears. When the cooling bed carryover deposits a bar on the aligning rollers, the bar moves
forward until its front end reaches a bar lifting sensor. If the front end of the bar does not reach
the sensor while in the first groove of the roller, the bar will continue moving when it is
deposited in the next groove of the roller, the bar will continue moving when it is deposited in

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the next groove of the roller. A bar being advanced by the carryover will occupy in sequence
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every notch (totally 5) of an aligning roller.

5.2.7.1.9 COL_CB_RTINlxx
The program for the Cooling Bed Run in Roller Table is written in the COL_CB_RTINLxx chart contains the
and shall be prosecuted.

following important blocks.

Introduction
The cooling approach table extends from dividing shear to the beginning of the cooling bed
extension.
The cooling bed run-in table extend from the beginning of cooling bed extension to the end of the
cooling bed.
Beyond the dividing shear in the runout tables, there will be a definite location where therollers must
increase in speed to insure that a gap is created between the tail end of the preceding bar and the
front end of the following bar. This gap is extremely important to accomplish the kickoff operation to
deposit only one bar per notch on the cooling bed.
The so called split in this section of cooling bed runout table rollers is accomplished by arrangement
of the number of roller drives controlled by each frequency inverter. The speed of one group of
rollers can therefore be increased individually without affecting the speed of the preceding group of
rollers.
Approximately 6.5 m at the receiving end of the roller table is comprised of two (2) pivoting
segments located at mill pass line level and one (1) fixed table segment located at a lower level.
The pivoting table segments are connected and supported by a common linkage arrangement which
allows each segment to be positioned simultaneously to either convey full length bars to the cooling
bed or to direct short tail cuts to the lower level fixed table segment.
Positioning of table segments is accomplished by air cylinder activation through the common linkage
arrangement.
Lift apron type brake slides are used to control the rod slow down and stopping position of the bar
on cooling bed.
Brief Description : The block contains all auxilliary functions and the logic for startup the drive generally,
interlocks, media signals, stop logic, test functions etc.
Mode of operation : The block is called cyclic in a scan cycle.
For details about interlock logic etc. please have a look in the block directly.

5.2.7.1.10 COL_SHE_SHEDIV
The program for the Devide Shear is written in the COL_SHE_SHEDIV
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chart & the Dyn.cut strategy for the shear is written in COL_SHE_SHEDIV
chart basic function of chart is that to connect signals to the HMI system
with the inter unit change thease both chart related to shear operation
contains the following important blocks.

CBSHFM

FM4501C1

VILBMAN
CBSHFM :
Brief Description :The block is handling the cutting length correction
CUTLGC and the impulse calculation CUTLGCIL for the counter of the
FM450. Also the general enable signal (interupt-logic with hardware-wire)
ENCYCUT is generated and the presetting of internal FM-parameters are
done during system start.
Mode of operation :Note: Internal call of the data block for the FM450-
control ! The block is called cyclic in a scan time cycle.

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Startup-functions : During system start the data block for the used hardware-counter module FM450 is
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setted with the module address ADDRESS and the channel number of the module CHANNEL. This values
are entered into the data block for the counter FM450.
Also the reference impulse value for the counter CUTLGCIL is presetted with the dummy value CUTLGPIL.
Entry data check : If the input value CHANNEL is not 1 or 2, then the output signal FM_PARA is setted. All
other functions will be blocked. This check is done only during system startup.
Cut length correction 1st cut : The calculation of the corrected impulse value of the cutting length for the
and shall be prosecuted.

first cut is done with the cycle impulse input signal ENCUT1.
Cut length correction 2nd cut and others : The calculation of the corrected impulse value of the cutting
length for the second and following cuts is done with the cycle impulse input signal ENCUTN.
Safety limitation of cutting length : In case that the calculated length or the available cut length CUTLG is
not valid (too short) the safety cut length for limitation CUTLGS is used. Then the output signal FM_CUTS is
setted.
General enable of cutting control : All conditions for cut enable are collected at the signals ENCYxCUT. If
all conditions are TRUE, the output signal ENCYCUT is active. With this output the interupt logic in OB40 is
enabled (hardware-bridge to IR-input).

FM450CYC :
Brief Description : The block is for handling and diagnostic of the
counter module FM450-1AP00-0AB0 from input channel 1 of the first
used counter module in the frame. Internally are called the function
blocks listed under "Remarks".
For detailed Information refer the Manual of the counter module FM450-
1AP00-0AB0. The block is written in FBD. Note: For the LHP only a part
of this block is used.
Mode of operation : The block supplies the interface of block
CNT_CTRL that controls the functions of the module FM450-1. In
addition the block is able to read out diagnosis data from counter
module FM450-1 by internally call of block DIAG_INF. For diagnosis the
block RDSYSST is required (if diagnosis shall be triggered by XINDIAG
= 1). For a better understanding refer also the manual of the FM450-
1AP00-0AB0.
unbefugte bzw. bestimmungswidrige Verwendung dieser
Der Inhalt dieses Blattes ist unser geistiges Eigentum. Die
Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

VICBSHA :
The block is for connecting signals to the HMI-system with internal
unit-change (connector SI_US) if necessary and selected.
The block covers display and data handling of the cooling bed
shear.
Mode of operation Note : The block is normally called cyclic in a slow
scan cycle.
Startup-functions : During system start the factors for unit change SI-US
are changed if the input value SI_US is active (1).

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CBSHCUT:
Brief Description : The block is handling the manual cutting lengths logic and the actual cut
counter logic within the data block DBCBSHCU.

Mode of operation : The block is called cyclic in a scan time cycle.


and shall be prosecuted.

In the data block for cutting DBCBSHCU following internal data areas (= length buffers) are in use:

LBMAN: LENGTH BUFFER MANUAL LENGTH


LBSHE: LENGTH BUFFER SHEAR CUT ACTUAL
For the cutting logic of the cooling bed shear the values in the LBSHE only
are used.
Cut counter logic: The cut counter logic for manual cuts is in use, if
the manual cut mode is selected (CUTMOD = 0). Then with each
cut CUTPOSP=1 the counter is moving like the settings for the five
different number of cuts MCUTNxR.

The output signals MCUTNxI are resetted if the cutting mode is in


auto CUTMOD=1 or the input ENMCUTP=1 (presetting).
Reactions to ENLBSHEP: IMP+ (ONE CYCLE)

DATA CHECK OF POINTER CUTTING LENGTH


PRESETTING CUTTING POINTER FOR NEXT BILLET (FIRST
PLACE)

Startup-functions:
During startup of the PLC following steps are done:

DATA CHECK OF POINTERS FOR LBMAN/LBSHE


LBMAN (length buffer manual): PRESETTING DURING STARTUP
WITH SAFETY CUT LENGTH (COMPLETE BUFFER)
LBSHE (length buffer shear actual): PRESETTING DURING
STARTUP WITH SAFETY CUT LENGTH (COMPLETE BUFFER)
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Entry data check:


Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

During startup and other parts of logic the datas for the length buffers are checked.

Length buffer manual length:


DBCBSHCUT.LBMAN_PLACE1 <= 0 or DBCBSHCUT.LBMAN_PLACEL <= 0 or MCUTLGS %lt;=
0 or TEMPCO %lt;= 0
If one of the conditions is high, the output signal FM_LBMAN is setted.
Length buffer shear cut actual:
DBCBSHCUT.LBSHE_PLACE1 <= 0 or DBCBSHCUT.LBSHE_PLACEL <= 0
If one of the conditions is high, the output signal FM_LBSHE is setted.

Enable of block functions:

Reactions to ENLBMAN: IMP+ (ONE CYCLE)

ENTRY OF SETTED (E.G. HMI) NUMBER OF MANUAL CUT LENGTHS

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ONLY THE TOTAL NUMBER OF LENGTHS WILL BE SETTED (REST AS IT WAS BEFORE !)
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PRESETTING DURING STARTUP WITH SAFETY CUT LENGTH (COMPLETE BUFFER)


FAULT MESSAGE IF ONE OF THE ENTRY DATA IS INVALID
Reactions to ENMANSHE: IMP+ (ONE CYCLE)

DATA CHECK OF POINTERS FOR LBMAN/LBSHE


and shall be prosecuted.

COPY FROM LBMAN INTO LBSHE COMPLETE


Reactions to ENCUTP: IMP+ ENABLE: PRESET MANUAL CUT COUNTERS
PRESETTING MANUAL CUT COUNTERS

Principal working of the block:


With a setting like this:
MCUTL1R = 70m MCUTL1N = 3
MCUTL2R = 75m MCUTL3N = 1
MCUTL3R = 80m MCUTL3N = 2
MCUTL4R = 85m MCUTL4N = 0
MCUTL5R = 0m MCUTL5N = 0
Number of cuts scheduled = 6
The cut buffer would look like this like this:
LBMAN_LG01 72.6 (MCUTL1R * TEMPCO) + LGCCROP
LBMAN_LG02 72.6 (MCUTL1R * TEMPCO) + LGCCROP
LBMAN_LG03 72.6 (MCUTL1R * TEMPCO) + LGCCROP
LBMAN_LG04 77.75 (MCUTL2R * TEMPCO) + LGCCROP
LBMAN_LG05 82.9 (MCUTL3R * TEMPCO) + LGCCROP
LBMAN_LG06 82.9 (MCUTL3R * TEMPCO) + LGCCROP
LBMAN_LG07..110 99.0 savety cut length MCUTLGS
All not used cut buffer will be preset with the savety cut length.
The shifting of the cut buffer after each cut will not be done in this block. Its only just to preset the
MAN cut length buffer and copy it to the active SHE cut buffer.
unbefugte bzw. bestimmungswidrige Verwendung dieser
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5.2.7.1.11 BAR_CT
The program for Tray Transfer & Sequnse for CB is written in the BAR_CT chart.

Introduction
The tray transfer system is used to lift the finished layer up from the transfer chain and traverse it to the
cooling bed run out roller. It then lowers the layer onto the cooling bed run out table.
The transfer stroke is 1940 mm from the collection (ambush) position to cooling bed run out table drop
position.

Description : The tray transfer system is using 7 ac motors driven by one VVVF drive. The motors are used
to transfer the carry between the chain transfer and cooling bed run out roller table. A tray lift hydraulic
double solenoid valve controls 7 cylinders which in unison lift and lower the tray transfer equipment as
required. A single solenoid valve is used to increase the lift speed.
The last three (3) trays, towards the straightening machine, will have a separate drive and
electromagnetically energized for an easier bar nose control and easy bar nose feed through straightening
device when processing angles. Tray transfer system operation 7 AC motors connected to one VVVF drive
are connected to the driving chain, which are moving

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the tray towards the cooling bed run out roller table or back to the chain transfer system. The motors are
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mechanically tied together on the secondary side of the gearboxes and together move totally 14 Trays,
which are located 6400 mm apart. Each tray has four blades 1600 mm apart. The motors are moving in
synchronization based on the voltage and frequency from the VVVF drive. The tray transfer lifts the bars
from the chain transfer when a layer has been finished according to the schedule on table 1. When the bar
are lifted the transfer moves the bars to the cooling bed run out table and positions them on the same slots
as the pockets on the tray transfer devices, the centerline of the layer must be positioned at the centerline of
and shall be prosecuted.

the Cold shear blades. When the bars are dropped on the roller table the tray transfer moves to pre lift
position under the chain transfer system and it getting ready to lift another layer as soon as it is finished.
The last three trays are Magnetic trays; magnets are energized when the tray is receiving the layer form the
chain and de-energized when depositing the layer into the cooling bed run out tables Tray transfer lift
system The double solenoid TRAY LIFT valve is controlling the lifting and lowering operation of the tray. In
lifting operation the speed must be set high to be able to lift the tray in between two rake cycles, this
achieved by the TRAY LIFT SPD ADJ single solenoid valve, energizing the Spd Adj valveincreases the
speed. The last 3 sections can be lifted separately or together with the main section of the Tray.

5.2.7.1.12 COL_SHE_DYCVIG This chart contain visulazation block for dynamic cut
strategy generais. This chart contain following techongological block

VISU CB DYN. CUT STR. PART


unbefugte bzw. bestimmungswidrige Verwendung dieser
Der Inhalt dieses Blattes ist unser geistiges Eigentum. Die
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Brief Description
The block is for connecting signals to the HMI-system with internal unit-change (connector SI_US) if
necessary.
Mode of operation
Note: Direct data access to the parametrized data block !

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The block is normally called cyclic in a slow scan cycle.


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Startup-functions:
During system start the factors for unit change SI-US are changed if the input value SI_US
active (1).

CUT OPTIMISATION VISU The blocks link all data to be displayed, per drive object (inputs and outputs),
to the HMI system (i.e. WinCC). A differentiation is made between ONLINE data and parameters
and shall be prosecuted.
unbefugte bzw. bestimmungswidrige Verwendung dieser
Der Inhalt dieses Blattes ist unser geistiges Eigentum. Die
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CUT OPTIMIZATION CALCULATION


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contrary to its intended purpose is not permitted

This block contain logic for cut optimization .


For details about interlock logic etc. please have a look in the block directly
and shall be prosecuted.
unbefugte bzw. bestimmungswidrige Verwendung dieser
Der Inhalt dieses Blattes ist unser geistiges Eigentum. Die
Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

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5.2.7.1.13 COL_GEN_GALARM
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ThIs chart contains the following functions

Genral functions for Alarm Intrupts

Incoupling & pulse generation fo intrupt signals


and shall be prosecuted.

Genral functions for divide shear cut logic.

Selection / Evaluation of Head / Normal / Tail cut


signals
Chart contains the following important blocks.

BYTE2
Brief Description : The block evaluates the status of a byte
for positive and negative edges. Thereby the block evaluates
single bits as well as the complete byte and indicates a
status change (see I/O description).

5.2.7.1.14 COL_GEN_GCY36
ThIs chart contains the following functions

Visuallization / Termination / Shedule Data / Csm for genral functions.

Genral functions for cyclic - intrupts

Incoupling & pulse generation fo intrupt signals


unbefugte bzw. bestimmungswidrige Verwendung dieser
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Genral functions for devide shear cut logic

Selection / Evaluation of Head / Normal / Tail cut signals

Genral functions blocks 1 / 2 / 3 : Nostop / Fack / Exiton / New Bar etc.

Genral logic for operation & run enable conditions 60s / 300s faults.
Chart contains the following important blocks.

CBGEN1CY

CBHOMPOS

REFREL

GAPMONI

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CBIMPIN
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CBMATTYP

CBGEN1CY :
Brief Description : The block is the part 1 for generating of general none
and shall be prosecuted.

time critical signals which are used in the complete cooling bed area.
Several signals / cycle impulses are generated. For detail logic please look
into the block.
This block read senser status in mill area & give output as in which area
material is present also a permission to new data transfer and new bar.

CBHOMEPOS :
This block gives output for the genral reset for all cooling bed drives
according to the input conditions of mill empty etc.
Brief Description : The block is handling the startup-signals, home
position, tracking reset logic and the general reset signal.
Mode of operation : The block is called in a slow cycle scan time.
The RESET is for all necessary blocks, flipflop etc. for resetting to a start-up
status (normally 0). This function is only allowed to set when the area is
empty !
With the output signal impulse GOHOME all drives, valvea etc. are moving
to theit home position.
For detail logic please look into the block.
unbefugte bzw. bestimmungswidrige Verwendung dieser
Der Inhalt dieses Blattes ist unser geistiges Eigentum. Die
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REFREL :

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This block use to indicate the ready status of drive also interlock for the
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prevent billet conditions through the o/p RECALL.


Brief Description : The block is for collecting the individual released
signals of the drives and generating the signal that all drives reference
value released RELALL.
Mode of operation : The block is called cyclic in a slow scan cycle. The
summary signal RELALL is active when all release signals RELDR01
and shall be prosecuted.

RELDR20 are active. The individual release signals can be simulated with
the SRELDR01 SRELDR20 (e.g. RELDR06 or SRELDR06). Also the
signal RELALL can be jumpered with the input signal SIMRELON without
any notice of the other input signals (RELDRxx or SRELDRxx).

GAPMONI :
This gap moniter block is use to moniter billet gap & also give commands
to exicutr gap chopping for shears as the same function block is use in
CTR so for more details please refre CTR description.

CBIMPIN :
Brief Description : The block is selecting, controling and monitoring the
actual needed impulses depending of the exit stand number XEXITNO.
Mode of operation : The block is called cyclic in a slow scan cycle.
Startup-functions : During system start the internal values are resetted.
Also the output signals.
Entry data check : For correct function the entry datas are being
checked. If SCHEDOK is not present or XEXITNO<1 or XEXITNO>20 or
NOCYC<20 then the output signal FM_ENTRY is setted and the internal
values as well as the control output commands STxxCOM are resetted.
Feedback monitoring : For the switching of the impulses relais with two
contactors have to be used. the second contact is for the feedback of the
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switching and incoupled for monitoring. If the feedback signal STxxFB is


not present after the time (NOCYC * CYCLE TIME) the output signal
FM_FBER is activated.

CBMATTYP :
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This block use to feed material I/P type to the tilting aprons as the I/P is read from DB & feed to the system
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whos correction is going to depend on material type such as Flat , Rebar , Hex etc.
Brief Description : The block is evaluating the material type ID and selecting the right output signal which
material is used.
Mode of operation : The block is called in a slow cycle scan time.
Check of entry datas : If the input value of XMATTYPE is out of range
(<1), the output signal FM_TYPE is setted.
and shall be prosecuted.

Selection of types : Depending on the material ID XMATTYPE


following possible materials are selectable:
XMATTYPE = 1: Round plain
XMATTYPE = 2: Round rebar
XMATTYPE = 3: Flat
XMATTYPE = 4: Hexagon
XMATTYPE = 5: Square
XMATTYPE = 6: Angle
This selectiois done once a time after schedule change NSCHDTP.
Acknowledgement : The output signal is resetted if the input value of the material type XMATTYPE is valid.

5.2.7.1.15 Enter-CPU Data Exchange


The send-receive blocks for communication with CTR and MIL CPU are placed in the COM chart. For
detailed description of the send-receive blocks, refer to the CTR CPU documentation.

5.2.7.1.16 COL_GEN_BARSIM - BAR SIMULATION LOGIC AND GHOSTROLLING LINE C


This chart contain HMD TEST , Bar Simulation & Bar Tracking functions. For further
details function see HMDTEST and Sequence block in CTR function.
DATCTR
The data from and to the CTR CPU is passed using TERM (Terminal) blocks via the chart DATCTR.
DATMIL
The data from and to the MIL CPU is passed using TERM (Terminal) blocks via the chart DATMIL.

5.2.5.2.2.1 5.2.7.1.17 COL_CB_SHPROL


The program for Pinch Roll is written in this Chart.
ThIs chart contains the following functions

Termination / Connection / Preset data for Pinch Roll.


unbefugte bzw. bestimmungswidrige Verwendung dieser
Der Inhalt dieses Blattes ist unser geistiges Eigentum. Die

Visuallization / Termination / Shedule Data for Pinch Roll.


Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

Logic for Pinch Roll auxiliary operation , start up & run conditions.

Description :
This chart contains the start stop of the pinch roll drive as the normal drive only the speciall part is the High
& Low Pressur pinching
The logic showing pinch roll high pressur pinchinging switching as its depend on the tracking sequnse

5.2.8 MIL / MED


According to Charts:
ALLSTD ALLSTD2 RTI (xx) RTE (xx)
PR (xx) WRT (xx) WEIGH_DEVICE DESCALER
STAND AUXILIARY FUNCTIONS ENTGEN GENRM
GENIM GENPM

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5.2.8.1 Drives switching and speed control


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There are mainly three blocks interconnected to switch modes SDV (setpoint enable devices)handle the
speed setting REF (setpoint selection, cascade, quickstop handling) and communicate to the drives MDV
(drive communication).
They are placed in each Roller Table & Pinch Roll chart on page C.
For engineering, normally on all three blocks doesnt need to be done anything. All blocks are pre
interconnected with each other and the visualisation blocks.
and shall be prosecuted.

The startup and run conditions are externally generated by corresponding interconnections.
The enable signals are reset when quick stop occurs and quickstop remains active at least until the drive is
stopped.

VISU
Brief Description
The blocks link all data to be displayed, per drive object (inputs and
outputs), to the HMI system (i.e. WinCC). A differentiation is made
between ONLINE data and parameters (only for maintenance purposes).
New data is copied to the ONLINE data by the signal "NEW
SCHEDULE" (NSC) at a pass schedule change. In addition, all
necessary data
is made available for restoring to the modification buffer.
Format conversions (i.e. from REAL to S5 TIME) are implemented and
static dialog signals deleted from the HMI when necessary.
Conversion from imperial units (i.e. feet, inch, mph, ...) to SI units (i.e. m,
cm, km/h) is exclusively implemented within the HMI.
Mode of operation
The rolling schedules and customer data transferred from level 2 can be
modified by the operator in the modification buffer and transferred
to the operation via the command New Pass Schedule to the Operation
NSC.The design also accommodates that the current operational
data (as optimized values) can be returned directly to level 2 via the
command Return Optimized Data OPT or intermediately saved in the
modification buffer via the command Restore Saved Data into the
Modification Buffer SAV.
unbefugte bzw. bestimmungswidrige Verwendung dieser
Der Inhalt dieses Blattes ist unser geistiges Eigentum. Die
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REF_AUX_DR
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contrary to its intended purpose is not permitted

The function of the setpoint generation is to pass a valid speed setpoint in


different operating modes to the drives. The specification of the rotational
speed setpoints for auxiliary drives, which must be adjusted to stand
speed, takes place via calculation from the material speed supplied by the
and shall be prosecuted.

respective main drive, the gear ratio and the effective diameter as well as
consideration of the leading/lagging factors.
The setpoint generation organizes a dynamic switching possibility to the
leading stand in each case and the appropriate factor, depending on the
bar travel.
(Example: Head/foot leading with pinch rolls).
Auxiliary drives are speed-wise assigned to a master (usually a main
drive), whose speed they follow with a leading factor. Switching between
4 speed masters is possible. If the drive is not speed-wise assigned to a
master the setpoints are located in the operating buffer of the pass
schedule.
Auxiliary drives can be, as main drives, individually jogged and manually
run. They are indirectly attached to the cascade controller and the
technological controls via the setpoint of their respective speed master.

Stand Auxiliary Functions


H_LOCK, H_PIN, V_PIN, V_LOCK, V_TRAV
In these charts all the auxiliary operations of stands are taking place.

Partition B contains the inputs to respective charts. All the related


interlocking takes place in partition C where all the interlocks are taken
care as per the ECS. FB_YR2 block is used for valve control operation.
Chart D is having actual outputs.

Brief Description:
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The block operates valves for two speeds and two directions. If the valve
Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

has only one speed, then the "Fast" inputs and outputs are left
unconnected. If the valve has only one direction, then the "Direction 2"
inputs are left unconnected. The limit switches are also left unconnected.
Unused inputs should then be configured as hidden in the CFC.
Method of Operation:
The block operates internally with the blocks MYR2 Valve Control, RKR2
Reversing Contactor Control and the system message block ALARM_8P
(SFB35) or MSGF for TDC.
The block has a display interface.
Configuring Remarks:
The block automatically determines its priority class for the time response.
Diagnostics Block:
The block can be configured with a diagnostics block. Therefore the inputs
MKR_CO2 can be used for the general interlocks and the inputs
RKR_C01, C02, C11-14 for direction dependent interlocks. The
acknowledgement of the diagnostics initial value detection is implemented
at the output RKR_YQT. The operating modes RKR_QM1-4 can also be
made known to the diagnostics block.

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5.2.8.2 Roller Table Auxiliary Functions


RTIx_COV, EJECTx
Roller table auxiliary function includes discard operation of billets & Roller table cover opening & closing.
Both the operation are manual. Solenoid valves are used for operation. Since this is solenoid operation
and shall be prosecuted.

FB_YR2 is used to control these operations.

5.2.8.3 Pinch Roll Auxiliary Functions


BPR COOL, PR ST 5H COOL, PR_01VAL, and PR_02VAL:
unbefugte bzw. bestimmungswidrige Verwendung dieser
Der Inhalt dieses Blattes ist unser geistiges Eigentum. Die
Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

Pinch roll auxiliary functions include Pinch roll cooling & Pinch roll open, close operation.Pinch roll cooling
starts when Pinch roll speed is above certain speed.

Pinch roll open, close operation depends upon material sensed by HMD & material in stand after pinch roll.
FB_YR2 block is used for the control of these operations.

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and shall be prosecuted.

5.2.8.4 Individual Stand Control


STDx :
All the stand related conditions are used in this chart to send to CTR CPU.
unbefugte bzw. bestimmungswidrige Verwendung dieser
Der Inhalt dieses Blattes ist unser geistiges Eigentum. Die

This chart actually enables the stand operation. All operation enable & run
Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

enable conditions are generated in this chart.


Partition B contains the stand Jogging enable operation & sent to CTR CPU.
Partition D contains the stand fault conditions. Stand lubrication fault or stand
fault conditions enables the fault & ultimately stopping the operation of mill.
Partition E contains all the messages & Ready conditions for the stand. These
messages & ready conditions are displayed on OS. If fault_01 occurs then the
corresponding Text_01 is displayed on OS.
Ready STD block is used as shown below:

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5.2.8.5 General Area Conditions:


and shall be prosecuted.

GENRM, GENIM, PMGEN


These charts are used to enable the mill operation of individual area. If the stands in the particular area are
healthy then that area can be operated individually.
Inputs from operating desks & Hand held for the operation of stands auxiliary are taken in these charts.
Since we have common inputs from desk for operation the
commands for the selected stands are taken. This is done with
following block. Also we have handheld operation unit.
Operation taken place from handheld is having higher priority
than desk.

5.2.8.6 Reference Selection for Auxiliary


Drives:
ENTGEN
Speed reference selection for roller tables drives are done in
this chart.
Depending upon the HMD sensing & Billet out request the
speed reference is toggled between Furnace roller table speed
& Stand speed.
Chart partition C selects the speed for roller table.

5.2.8.7 Stand Cooling:


RIMCOOL
Stand cooling logic for all the stands are in this chart. Stand cooling can be done in auto as well as in
manual mode. When Speed of stand is above 10% of set speed then the cooling for the stand is started.

5.2.8.8 Communication:
unbefugte bzw. bestimmungswidrige Verwendung dieser
Der Inhalt dieses Blattes ist unser geistiges Eigentum. Die

COM
Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

Communication with other CPUs takes place in this chart.


Ethernet communication
This connection is defined and parameterized in the
Hardware, the Connections and the chart COM.
In the Hardware you define for the CP443-1 which kind of
Ethernet communication will be used. In our mills we
normally use ISO/OSI which means you have to define a
Ethernet MAC address. But a TCP/IP connection would
also work without the necessarily of changing the program.
In the connections all partners of this CPU need to be set
up.
In the chart COM there are send and receive blocks for
every connection included.
Description of Send Receive
One connection can consist of several send and receive
blocks (like CTR-SHE one for schedule data, one for
actual data). During engineering check that the ID of the
communication blocks is according to the setting in the

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connections (ID may change if connection table is changed)


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The unauthorized use of this documentation or use
contrary to its intended purpose is not permitted

The R_ID on both CPU of one connection need to be the same, but it is only allowed to use it once in the
project. Take care for the length setting LE_S of the DB, especially after changing the communication DB.
There is always a sending and a receiving DB for one connection, for example DBMILCTR (sending from
MIL to CTR) and DBCTRMIL (receiving MIL from CTR). These two data blocks have to be the same in both
CPU.
Tipp: if the communication block shows an error, but the physical
and shall be prosecuted.

connection itself is ok, then set input PULSE/MON_TIME at the


communication blocks to 0 on both sides.

5.2.8.9 Rectifier Control:


RECT
This chart is used for the controlling on off operation of rectifiers.
The block executes the interface to a SINAMICS INFEED module.
Mode of operation
The Block calls internally a group of blocks from the TMBASE library
blocks which are necessary to link a position controlled shear drive
to the CSM and the reference value system.
In principle the basic function is similar the SIN_MDV.
The block links the basic automation (S7) to infeed module via
PROFIBUS by an internal call of the receive block SFC14 and the
send block SFC15 for L2DP telegram.
The functions of central switching and monitoring CSM are carried out
by an internal function. The block executes the link to HMI reading the
commands for switching the inverter and supplying the
information of drive status for HMI. For switching the inverter the
block writes to the drive control word. Thereby the block
evaluates the start, stop and running conditions for the drive as
well as emergency functions and the status telegram from drive.
The switching of inverter is supervised by monitoring time
CSM_TS.
The block drive interface to infeed module, SIN_INF offers a
drive simulation for engineering by switching the input
ENG_SIM to simulation mode. In case of command ENG_SIM
the inverter decelerate to stop by setting bit ON to 0 (S_PZD1),
the drive is switched off, L2DP-communication is cut off. The
receive telegram from drive is not evaluated, the drive functions
are simulated.
unbefugte bzw. bestimmungswidrige Verwendung dieser
Der Inhalt dieses Blattes ist unser geistiges Eigentum. Die

Furthermore the block SIN_INF generates the commands for


Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

the drive control words and supplies all drive data for the send
L2DP telegram. Moreover the block evaluates the status L2DP
telegram from drive and supplies the corresponding data for the
basic automation.

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5.2.8.10 GENERAL CHARTS


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ALLSTD, ALLSTD2
In these charts desks inputs are taken & passed onto other charts. Also WLH signals from are taken &
passed to other charts.
Motor bearing temp. are read & processed in this chart which generates the alarm & warning temp. signals
of stands. With any of the temp. exceeding the warning or alarm limit set at input side the output alarm or
and shall be prosecuted.

warning is generated.

5.2.8.11 Mill Entry Auxiliary Operations:


BILLET_LOAD, WEIGH DEVICE
These charts contain the auxiliary operation sequences that take
place in Mill entry area. There are total 3 auto sequences. These
sequences are for loading of Billet from skid to furnace.
Billet skid sequence & Billet Loader sequence loads the billet from
billet skid to furnace roller table.

WRT Charging sequence takes billet from billet skid roller table onto
furnace roller table. If the furnace roller table are empty then roller
tables start moving in the direction of furnace letting the skid to move
inside the furnace. The speed synchronization is done depending on
the skid position.
unbefugte bzw. bestimmungswidrige Verwendung dieser
Der Inhalt dieses Blattes ist unser geistiges Eigentum. Die
Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

5.2.8.13 DESCALER
To remove scale from Billet Descaler is used, this high power water spary on hot billet which used to
remove scale on billet. Logic for on/off the descaler is shown

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unbefugte bzw. bestimmungswidrige Verwendung dieser The unauthorized use of this documentation or use
Unterlage ist nicht gestattet und wird gerichtlich verfolgt. contrary to its intended purpose is not permitted
and shall be prosecuted.

5.2.8.14
Merchant Bar Mill

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5.2.9 Emergency System :

5.2.9.1 General
and shall be prosecuted.

This External Specification describes the emergency stop safety sequence which will be observed in the
Mill area as per E-STOP matrix.
In the mill, there is hardwired emergency logic designed as per HW Estop Matix in parallel with
software logic. Separate Hardwired ESTOP panel is made with contactors for hardawired logic. Main
purpose of hardware E-Stop panel is :

When the E-Stop button is actuated, Fast Stop Uncoordinated and then block firing pulses
when speed is zero.

It should not be possible to restart the machine from a remote location without first clearing
the dangerous situation. The EMERGENCY STOP device must be released "locally".

The EMERGENCY STOP device must have priority with regard to all the other functions and
operations in all operating modes.

5.2.9.2 Emergency Stop On Operating Stations


All UHD/UHP has E-stop Mushroom head Latchable Push-buttons.
The effect of all these E-Stops are different on different drives depending upon process requirement and as
mentioned in Fault and E-Stop matrix.
Each E-Stop MHPB has two 'NC' type contact element. One contact has been taken as a digital input in
PLC. The other contact is used in E-stop Panel.
There is one Emeregency Reset Push button on CP2. It has two 'NO' type contact element. One contact
has been taken as a digital input in PLC.The other contact is used in E-stop Panel.

5.2.9.3 Emergency Stop Panel


Emergency Panel Contactor logic works on 230VAC control Voltage.
With Emeregency Reset 'NO' contact two contactors K10 and K11 are picked up. These contactors are
used to RESET estop contactor after that area E-STOP MHPB is released.
Contactors K12 to K32 are for individual E-Stop on OS. These contactors are used to latch E-stop condition
unbefugte bzw. bestimmungswidrige Verwendung dieser
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if MHPB is pressed. This will be remain latched evenif MHPB is released. Estop will be cleared after RESET
Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

from MP2.
There are some emergency groups defined in E- Stop Matrix. These determine which drives to be stopped
for that MHPB emergency at specified OS pressed. Contactors K41 to K48 are configured as per E-Stop
matrix. Each of them represent a Emeregency logic group. e.g. K41 will be ON if there is no E-Stop in MP2,
OS2 & OS 3. etc
One NO contact of each of these contactors is given to PLC as digital Input. If PLC is also detecting all the
Emergency healthy in OS, It sends a potential free digital output for each emergency group. This output is
kept in series with corresponding logic group contactor (as K41) to make another contactor (as K51) ON.
So, for each contactor from K41 to 48, there is one contactor from K51 to K58 respectively.If hardwired
emergency to E-stop panel and PLC emergency both are healthy for a emergency group, corresponding
contactor (K51 to K58) becomes ON.
Aux. Contacts of K51 to K58 are used in Sinamics Motor Modules OFF3 (Fast Stop). These contacts are
wired up to CU320 DI terminals. Then it will be parameterized as OFF3 in corresponding drives.
Parallely there will be OFF3 command issued to drives Control Word via profibus by PLC.

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5.2.9.4 Emergency Stop Matrix


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The unauthorized use of this documentation or use
contrary to its intended purpose is not permitted
and shall be prosecuted.
unbefugte bzw. bestimmungswidrige Verwendung dieser
Der Inhalt dieses Blattes ist unser geistiges Eigentum. Die
Unterlage ist nicht gestattet und wird gerichtlich verfolgt.

5.2.9.5 Drive's Response to Emergency


Emergency from E-Stop panel (hardwired) and from PLC (through profibus) will be acted to Fast Stop Action
in the motor. While all the SLM Infeeds (Rectifier) will be healthy.

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