Millmate Roll Force Systems

Stainless load cells for roll force measurement in hot and cold rolling mills

General System Description

The Millmate Roll Force System has been specially developed to handle very fast force changes in a rolling mill. The system consists of load cells with matching units, panel unit and control unit. All signal processing is analogue, and the monitoring and control of the analogue signal is digital. The digital part of the system also contains functions such as signal path testing and signal parameter adjustment. The system contains a microprocessor to handle the digital functions. All communication with the system and all signals that influence the operation of the system are controlled and processed by the microprocessor.

Microprocessor technology enables the operator to communicate with the measurement equipment and, for instance, to obtain rapid reports on its condition. If the operator activates the SYSTEM TEST function, the voltages, currents, insulation levels, trancducer operation, etc. of the entire system are tested.

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The block diagram shows the active parts of Millmate Roll Force System: 1. Control unit 2. Panel unit 3. Matching unit 4. Load cells 5. Computer/VDU 6. Printer

4 2 3 5
Units 5 and 6 are external units that can be connected to the system via its standard V24 interface

Principle of measurement
Pressductor Technology

The operation of the Millmate Roll Force Load Cells are based on the well-known Pressductor Technology, the magnetoelastic effect, according to which the magnetic properties of steel are influenced by mechanical forces acting on it. The transducer in the load cell (see illustrations) has four holes through which pass two windings wound so that they form a right angle with each other and positioned at an angle of 45 to the direction of the force to be measured. One of the windings (the primary, a) is supplied with alternating current and the other (the secondary, b) is a measuring winding. Since the two windings are at right angle to each other there is no magnetic coupling between them as long as there is no load on the transducer. However, if the transducer is subjected to a mechanical force, the permeability of the material for the magnetic flux is reduced in the direction

of the force. This gives rise to a change in the symmetry of the magnetic flux, so that a voltage is induced in the secondary winding. Up to a given load, the induced voltage is proportional to the load. In Millmate Roll Force Load Cells there can be up to 1500 transducers, so that even if the load is unevenly distributed, the measurement result will nevertheless be correct. In a Millmate Roll Force Load Cell the transducers are equivalent to the load cell. The load cell is made from specially developed stainless steel electro-sheet with the profile shown in the illustration. The unique Pressductor Technology makes it possible to design the measurement zone optimally with slots between measurement zones to overcome the effect of lateral forces. Among other benefits, this design approach also minimises the height of the load cells.

Pressductor Technology The transducer is energised by the primary winding (a). A voltage proportional to the applied force is generated in the secondary winding (b).

The measurement principle is based on the magnetoelastic effect, according to which the magnetic properties of a material are influenced by mechanical stress.

Installation Arrangements

To achieve the best possible measurement results, certain basic rules must be observed when installing the load cell: The entire force must pass through the load cell. The force must be measured as close to the source of the force (the roll gap) as possible. The load cells must be protected to the greatest possible extent from high bending, lateral and torsional forces. In most mill stands the roll gap is controlled with hydraulic positioners and/or mill screws. Load cells can be installed in several different ways, but the preferred arrangement, from both the financial and technical points of view, is usually to install the load cell under the mill screw. Currently there are three types of load cells in the product range, load cells for installation under the mill screw, between the mill nut and the mill stand and those for installation under the lower back-up roll bearing.

ABB has long experience of load cell installations It is essential to take every factor into account if an optimal installation is to be achieved. For instance, good load distribution over the surface of the load cell is essential. ABB has many years of experience of installing load cells in all types of rolling mills, and uses modern calculation methods such as the Finite Element Method (FEM) to work out the best solutions in every individual case. This, together with the fact that the Millmate Roll Force Load Cells have been specially designed for roll force measurement, provides the right conditions for the best possible results.

Installation with hydraulic positioners In installations with hydraulic positioners, the load cells can be integrated with the other mechanical parts of the positioner, i.e., in the moving piston. Since the positioner is a precision-made unit, the tolerance requirement of the load cell can easily be met. Even the hydraulic pressure ensures that the load is properly distributed.

1. Bearing plate 2. Pressure plate 3. Load cell

4. Plunger 5. Cylinder

1. Under the mill screw For installation under the mill screw, the load cell can be combined with thrust bearings and pressure plates into a package movably attached to the mill screw; this makes for easier roll changing. The arrangement gives good force distribution, simple, inexpensive installation and easy servicing. In addition, there is no need to machine any surfaces on the roll stand. However, the arrangement does take up space in the roll window.

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2. Under the lower back-up roll bearing There must be a sufficiently large flat surface on the lower part of the roll stand if the load cell is to be installed under the lower back-up roll bearing, but this arrangement has the advantage that there is no need to pay particular attention to the load cell on the roll changing, and it is well protected.

3. Annular load cell between the mill nut and mill stand This variant makes it possible to measure even if the space under the mill screw and under the lower back-up roll bearing is insufficient. This arrangement also has the advantage that there is no need to pay particular attention to the load cell on the roll changing, and it is well protected. 5

Description of the Millmate Roll Force Load Cells

Millmate Roll Force Load Cells contain no moving parts and are designed for very severe duty.

The product range includes rectangular, annular and circular load cells in several standard sizes, with measuring ranges from 0.63 MN to 60 MN.

Millmate Roll Force Load Cells have a core consisting of highstrength stainless steel laminations bonded together under high temperature and pressure with an extremely strong oil- and chemical-resistant epoxy adhesive. They therefore contain no moving parts and are designed for very severe duty. The cables for primary and secondary windings are in fluoroplastic-insulated, resistant to oil, humidity and dirt. The built-in calibration and temperature compensation of the load cell are made up of high-stability components encased in a protective box of fluoroplastic. Due to its low impedance and high output signal the Millmate Roll Force Load Cell has extremely low sensitivity against insulation defects and maintains its measuring accuracy down to 10 k insulation level. The load cell output signals are calibrated for full interchangeability between load cells of the same type and size. The various types and the wide load range will cover practically all conceivable roll force measurement applications.

Circular load cells A circular Millmate Roll Force Load Cell of type PFVL 101C is generally used for installation under the mill screw. Shrunk-on steel rings protect the load cell windings and underlying components. There is a choice of core diameters in multiples of 30 mm, giving 23 different standard sizes for forces between 1.6 and 60 MN. Rectangular load cells Rectangular load cells type PFVL 101V are primarily used for installation under the lower back-up roll bearing, but can in certain cases also be used under the mill screw. The load cell can be adapted to required dimensions, and the length is chosen as a multiple of 30 mm. For load cells longer than 900 mm, the chosen length must be a multiple of 60 mm. The width is chosen as a multiple of 30 mm. This load cell type is available in standard sizes from 0.63 to 56 MN. Annular load cells Annular load cells type PFVL 101R are usually installed between nut and roll stand. The annular load cell consists of measurement plates wounded on an annular iron core, after which an outer iron ring is shrunk on to the load cell to protect the windings and the components below it. Standard sizes of annular load cells are available from 2 to 28 MN and listed in the table on page 15. Load cells with other dimensions can be manufactured to order.

Load Cells - Data and Definitions

Accuracy class Linearity deviation Hysteresis Repeatability error Compression Calibration error

% of Fnom % of Fnom % of Fnom % of Fnom (mm at Fnom)

0.5 0.5 0.2 0.1 0.05 0.1%

Compensated for min. error Zero point drift Sensitivity drift Working temperature range* Storage temperature range
*) Max. permitted temp. short term

+20 +80C 0.01%/C 0.01%/C -10 +90C -40 +90C

+110C

Data

Overload capacity The figures apply provided that the force is uniformly distributed over the load cell surface, at a nominal force equivalent to 100 N/mm2 on the pressure surface of the load cell. In certain cases it may be appropriate to dimension the load cell differently, and a higher overload capacity can then be achieved. Nominal load (Fnom) is the load for which the load cell is dimensioned and calibrated, i.e. the sum of the stationary load and the maximum measured load in the measuring direction. Accuracy class is defined as the maximum deviation, and is expressed as a percentage of the sensitivity at nominal load. This includes linearity deviation, hysteresis and repeatability error. Linearity deviation is the maximum deviation from a straight line drawn between the output values of zero and nominal load, related to the nominal load. Hysteresis is the maximum deviation of the output signal at the same load during a cycle from zero to nominal load and back
U Linearity deviation U

Highest permissible load without permanent change of data.

Highest permissible single loading without mechanical damage to the load cell. 700% of nominal load

300% of nominal load

to zero, related to the sensitivity at nominal load. The hysteresis is proportional to the cycle. Repeatability error is defined as the maximum deviation between repeated readings under identical conditions. It is expressed as a percentage of the sensitivity at a nominal load. Compression is the total reduction in the height of the load cell when the load is increased from zero to nominal load. Zero point drift is defined as the drift in the output signal when there is no load on the load cell. Sensitivity drift is defined as the drift in the output signal at nominal load, excluding the zero point drift.
U Sensitivity drift

Definitions

Hysteresis

Fnom

Fnom

Zero point drift

Fnom

Control Unit

PFVA 131 For induvidual measurement of two load cells. PFVA 131S For induvidual measurement of four load cells.

The control unit of the Millmate Roll Force System both controls and monitors the measuring equipment and its functions. The operator uses a panel unit to communicate with the system, i.e., to give orders, to read and alter data, to obtain status information and so on. The system can be remotely controlled from the operators control cabin or directly from an overriding computer. Microprocessor technology makes it possible to monitor the entire system con-

tinuously. In addition, by activating the SYSTEM TEST function, the operator can himself test the voltages, currents, insulation level, transducer operation, etc., of the entire system. This function can also be activated by an overriding computer. A Millmate Roll Force System can be built up in various ways. Several control units can be installed in the same cabinet.

Communication with computer or other equipment Via its microprocessor, the Millmate Roll Force System can communicate with an overriding computer, as well as printers and visual display screens. Communication goes via a V24 interface, so that messages may be both sent and received. This means that an overriding computer can control the Millmate Roll Force System in the same way as an operator at the panel unit. System messages and data can be obtained in the standard ASCII code for direct display on a screen or output to a printer. 8

Digital inputs/outputs The digital inputs are used to activate a number of the system functions, including zero setting, major system test and single load cell operation. The digital outputs are used to give information on the status of the different parts of the system. Statuses that can be monitored include: step detector, level detector, single load cell operation, load cell supply, system locking and system errors.

Panel unit

Manual communication with the Millmate Roll Force System takes place via a panel unit. The operator communicates with the system via pushbuttons, LEDs and a digital display. The panel unit has the following control and indication functions: Function pushbuttons. All pushbuttons are equipped with LEDs for status indication. Numerical keys for the entry of numerical data. SEND. Used to initiate transmission of data to the system. The LED of this pushbutton lights up if transmitted data are not accepted by the system. CLEAR. This pushbutton is used to change data already entered. It can also be used to return to previous prompts. LEDs for status indication of lock, step and level indicators. Seven-digit display.

Functions With the panel unit, a number of functions can be activated by entering a number on the numeric keypad. For some of the most commonly used functions there are dedicated keys on the panel unit. These are shown on the right hand.

ZERO SET The signals from both load cells are reset to zero on this command. DPM Digital Panel Meter. The present signal/load is displayed on the selected channel in the selected units. LD Level Detector. Eight level detectors, which can be individually allocated to any chosen channel. Output signal via optocoupler and LED on panel. SD Step detector. Indicates rapid changes in the sum signal. Adjustable time and step height. Output signal via optocoupler and LED on panel. SCA & SCB Single Cell A/B. Disconnects one load cell and feeds the signal from the other to both measurement channels. Indication via optocoupler and LED on panel.

GAIN Measures the adjustable gain continuously in the relevant measurement channel. EXC Switches the excitation current to the load cells on/off. TEST Tests the entire system (including cables and load cells) at 31 points and gives diagnoses. LIST Function key, the functions of which include listing of error messages and setting the communication format. LOCK The equipment can be locked via a digital input to prevent unauthorised changes of system parameters. This is indicated at a digital output and by a LED on the panel.

Digital Inputs 24V LOCK ZERO SET SYSTEM TEST STEP DETECTOR SET/RESET EXCITATION CONTROL CONTROL UNIT

Digital Outputs 24V CPU RUN LOCKED SYSTEM SYSTEM ERROR ILLEGAL COMMAND SINGLE CELL EXCITATION ON STEP DETECTOR LEVEL DETECTOR 1 LEVEL DETECTOR 2 LEVEL DETECTOR 3 LEVEL DETECTOR 4 LEVEL DETECTOR 5 LEVEL DETECTOR 6 LEVEL DETECTOR 7 LEVEL DETECTOR 8

Only PFVA 131S

Performance and Data

Mains voltage

100-127, 200-240 V, -15/+10% Mains frequency 45-65 Hz Power consumption 800 VA (P.F.0.7) Environmental data Temperature range 0C to +55C Degree of protection MNS Select cabinet IP 21, ventilated IP 54, sealed Wall cabinet IP 65 Min. temp. for transport and storage -40C Performance Signal outputs

Process and instrument outputs for sum, difference and partial-force signals. The instrument outputs can be switched for voltage or current and are adjustable with potentiometers. Output signal 10 V for the sum signal (5 V selectable) Nominal 5 V for the difference signal (can be amplified 10 times selectable) and 5 V for the partial-force signals. The output signal gain can be adjusted in the range of 0.4 - 2.0 times. Output current, max.5 mA total per channel Ripple, max. 5 mV, p-p 10 kHz bandwidth

Step response time {0-98%} = 1 ms {0-90%} = 0.7 ms overshoot = 0% instrument output = 1.1 s 0-90% Limit frequency 600 Hz process output 0.3 Hz instrument output Non-linearity, max. 0.01% of measuring range Temperature dependence Zero point 0.005%/C Sensitivity 0.005%/C of the actual signal Mains voltage dependence 0% within the stated range Frequency dependence 0% within the stated range Analogue inputs 5 V DC, one input per channel Impedance 10-20 k Digital inputs isolated, 24 V DC, <10 mA Digital outputs isolated (opto), 24 V DC max. 200 mA Serial communication RS-232/CCITT (V24) 75-9600 baud

Electrical interference environment As per EMC Directive 89/336/EEC Electrical safety As per Low Voltage Directive 73/23/EEC

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Assembly

Assembly arrangements The electronics of the Millmate Roll Force System are in the form of plug-in units conforming to the international 19 standard. There are two standard installation arrangements: PFAS 112 Cabinet With space for one control unit. MNS Select Cabinet With space for four control units.

2225

760

65 6

35 0

356

740

600

483

MNS Select

PFAS 112 11

Equipment frame

35 0

Interface Units and Accessories

Matching unit To convert the excitation current from 2 A to a higher current, 25 A, there is a matching unit PFVO 102 that can be located up to 25 m away from the relevant load cell (depending on the nominal load). Each load cell requires one matching unit, which is interchangeable between load cells. PFVO 202 (2 A to 5 A) is needed for annular load cells with nominal load 8 MN. Insulation amplifier DSTY 101 The insulation amplifier can be used when electrical insulation is required, for example between input and output or between supply and input/output. In such cases the insulation capacity is 3 kV 50 Hz, 60 s. Supply voltage +24 V (18-36 V) Current consumption 70 mA + external load Signal ranges Input 0-2, 0-5, 0-10 V 0-20, 4-20 mA Output 0-10 V 0-20, 4-20 mA Relay board PFVK 128 Fitted with four relays with one changeover function per relay. The board is supplied with 24 V DC. Power consumption 20 mA/relay Contact data AC: 8 A at 250 V DC: 1.2 A at 48 V 0.2 A at 220 V 19 aluminium frame DSRA 101 For mounting the insulation amplifier and the relay board.

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Guide to Ordering
Rectangular load cells type PFVL 101V

Standard sizes and cable lengths 45 Nominal load Max cable length (MN) (m) 0.63 25 0.80 25 L 1.0 25 1.25 25 1.6 25 2.0 25 2.5 24 3.1 23 4.0 22 5.0 21 6.3 20 8.0 19 10 18 12.5 17 Length (L) mm 14 16 120 480 16 16 150 510 18 15 180 540 20 15 210 570 22 14 240 600 25 13 270 630 28 12 300 660 31 11 330 690 35 10 360 720 40 8 390 750 45 8 420 780 50 6 450 810 56 6 Order as follows: Determine the load for which the load cell is to be used and choose from the table the next higher value in the standard range. Determine either the width or length of the load cell and calculate the other dimension using the following formula: L x W x 0.0001 = F

74

40

40

840 870 900 960 1020 1080 1140 1200 1260 1320

Width (W) mm 70 430 100 460 130 490 160 520 190 550 220 580 250 610 280 310 340 370 400

Example Nominal load 14 MN and a width of 370 mm will be 390 mm long (rounded up from 378). PFVL 101V, 14 MN, L=390 mm W=370 mm

L = load cell length in mm W= load cell width in mm F = nominal load of load cell in MN (taken from the standard series in the table) The width and length are rounded up to the next higher value in the table.

When ordering, please state: type designation nominal load width and length

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Guide to Ordering
Circular load cells type PFVL 101C

Example Nominal load 20 MN per load cell. Select 20 MN load cell, dimension OD=560 mm, ID=510 mm PFVL 101C, 20 MN.

Standard sizes and cable lengths Load cells are manufactured in the standard range as below: Nominal ID OD Max. cable load (MN) (mm) (mm) length (m) 1.6 150 210 25 2.5 180 240 24 3.1 210 270 23 4.0 240 290 22 5.0 270 320 21 6.3 300 350 20 8.0 330 380 19 10 360 410 18 12.5 390 440 17 14 420 470 16 16 450 500 16 18 480 530 15 20 510 560 15 22 540 590 14 25 570 620 13 28 600 650 12 31 630 710 11 35 660 740 10 40 720 800 8 45 750 830 8 50 780 860 6 51.5 810 890 6 60 810 890 6

74 OD ID

When ordering, please state: type designation nominal load

Order as follows: Determine the load for which the load cell is to be used and choose from the table the next higher value in the standard range.

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Guide to Ordering
Annular load cells type PFVL 101R

74 L

D1 D2 D3 D4

Standard sizes and cable lengths Nominal D1 D2 D3 D4 load (MN) (mm) (mm) (mm) (mm) 2 100 130 200 240 2.5 100 130 210 250 3.1 200 230 300 340 4 225 255 340 380 5 255 285 380 410 6.3 285 315 420 450 8.0 320 350 470 500 10 355 385 525 555 11.2 375 405 550 580 12.5 400 430 590 620 14 420 450 620 650 16 450 480 660 690 18 480 510 700 730 20 505 535 735 765 22.4 535 565 775 805 25 565 595 820 850 28 595 625 865 895
Other dimensions on request

Max cable length (m) 75 72 69 66 63 60 57 18 17 17 16 16 15 15 14 13 12

Example PFVL 101R, 10 MN, D2=385, D3=525.

Order as follows: Determine the load for which the load cell is to be used and choose from the table the next higher value in the standard range. We can customise load cells if a standard load cell is not suitable for a particular application. To calculate the load F for non-standard load cells F=

When ordering, please state: type designation nominal load D2 and D3

(D 4 -D 4 )0.0001 MN.
3 2 2 2

ABB Automation Products AB reserves the right to change design, data and dimensions without prior notification.

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ABB is a world-wide organization committed to providing solutions for the generation, transmission, distribution and use of electrical power. It consists of 1000 companies in 140 countries. As part of that group ABB Automation Products is one of the worlds largest suppliers of industrial automation, products and services. Unique global resources provide the highest levels of customer value growing from indepth knowledge and understanding of industry needs. Leading edge technology, specific application knowledge and an uncompromising commitment to quality make ABB Automation Products an important partner for industries in their drive for productivity, quality and profitability. ABB Force Measurement is a division within ABB Automation Products. It provides equipment for accurate, reliable measurement and control in a broad range of applications from steel making to paper converting industries.

Pressductor is a registered trademark of ABB Automation Products AB

ABB Automation Products AB

S-721 59 Vsters Sweden Phone: +46 21 34 20 00 Fax: +46 21 34 00 05 Internet: www.abb.com/pressductor

We have local representatives in:

Argentina Buenos Aires, Australia Melbourne, Austria Vienna, Belgium Brussels, Brazil So Paulo, Canada Montreal, Chile Santiago, China Beijing, Denmark Odense, Finland Helsinki, France Dcines, Germany Dsseldorf, India Bangalore, Indonesia Jakarta, Italy Milan, Japan Tokyo, Korea Seoul, Malaysia Kuala Lumpur, Mexico Guadalajara, South Africa Johannesburg, Spain Bilbao, Taiwan Kaohsiung, Thailand Bangkok, United Kingdom Manchester, USA Brewster N.Y., Venezuela Caracas

3BSE003372R0301

Vstra Aros Tryckeri 1998-11