Sendzimir

Mill Management
System

for

Reversing Cold
Rolling Mills
 Sendzimir Mill Management System
Introduction
The Mill Management System (MMS) is a set
of computer programs designed to be used by
the operator of a reversing type rolling mill, using
a computer located at the operator's desk, or
nearby.
The main program of the set utilizes a
mathematical model of the rolling process to
generate optimum pass schedules for the mill,
and to set up the mill accordingly.
Any suitable computer using IBM PC-DOS or
MS-DOS operating system can be used,
although, for the mill environment we
recommend a "ruggedized" machine such as the
IBM Industrial PC. Versions of the software are
available for operation under DOS or "Windows"
environments.
A printer can be used to record the results of
the computation, if desired.
Since the program incorporates mill variables
(such as Mill Power, Winder Tension, Mill
Speed) that only apply to one particular rolling
mill, it cannot be transferred to another rolling
mill in your plant. We can also supply additional
programs for other mills in your plant. Programs
are available to work in inch units or metric units.
Versions of the software are available for
Sendzimir 20-High mills, and also for 6-high, 4-
high and 2-high cold rolling mills.
We want you to be happy with the software,
and, included in our price is a service to make a
reasonable number of modifications and
refinements during the first year of use, in order
to tailor the program to your liking.
Speed of Computation - Multiple pass
schedules are optimized and displayed within
one second normally.
The MMS is covered by US Patent no.
4,745,556 and corresponding patents in other
countries.
Main Pass Schedule Objective
(1) To enable maximum reductions and rolling
speeds to be utilized at all times, thus
maximizing production rates.
(2) To achieve more consistent production
rates from shift to shift, by running the
same optimized schedules on every shift.
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(3) To give new mill operators continuing
instruction in setting up the mill - such as
determining effective pass reductions,
strip tension and speed settings.
(4) To take the guesswork out of the selection
of intermediate gauges.
(5) To balance the Roll Separating Force from
pass to pass, in order to achieve more
consistent flatness, and minimize the
requirement for changes in mill profile
settings from pass to pass.
(6) To re-schedule the remaining passes to
give maximum pass reductions, and
balanced Roll Separating Force from pass
to pass if the actual schedule deviates
from the planned pass schedule for any
reason, and at any point,
(7) To achieve all of the above regardless of
what material is rolled, and regardless of
width, starting gauge and final gauge or
combinations thereof.
Since the number of possible
combinations of these factors is infinite, it
is not possible to store schedules for all
cases. Therefore, a computer located at
the mill is the logical method to adopt, and
the Mill Management Software enables
the computer to achieve the objectives.
(8) To provide automatic setting of thickness
gauges and mill speed and tension
settings, and to provide for operator trim of
any settings, with automatic re-scheduling
of remaining passes required as a result of
operator changes (on mills equipped with
interfaces from mill management
computer to AGC or thickness gauges and
mill drive control systems).
(9) To provide a system for storing actual
gauge data for each coil rolled, for
subsequent analysis by QC Department,
and for generation of coil reports for
customers, and to provide a system for
storing values of other rolling variables for
use in troubleshooting and in refining the
working of the system.
(10) To provide a system that can interface to
plantwide (level 2 or level 3) computer
systems for automatic transfer of data
back and forth.
(11) To provide a system enabling entry of data
for coils on a remote computer, minimizing
the time required by the operator for
setting up the mill.
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 Sendzimir Mill Management System
(12) The program, unlike pre-programmed
pass schedules, can be used to set up the
mill automatically, regardless of whether
the same starting/finish
gauge/width/material combination has
previously been rolled on the mill.
(13) The program is designed to take the
maximum reduction on every pass,
consistent with available mill power or Roll
Separating Force, and with avoidance of
roll skidding.
The program has three main routines
summarized below:
The Optimizing Routine
The optimizing phase establishes the
minimum number of passes needed by the mill
to achieve the desired final gauge. A complete
optimized pass schedule is computed, where
maximum reductions are taken on every pass
except the last. The last pass is merely a "fill-in"
pass that gets the gauge down to the final gauge
from the last optimized pass.
For example, rolling from 0.050" down,
supposing optimized reductions in a given case
were:
Entry Exit % The rationalizing phase thus establishes a
Pass Gauge Gauge Red.
1st 0.050" 0.037" 26%
2nd 0.037" 0.030" 19%
3rd 0.030" 0.025" 17%
4th 0.025" 0.020" 20%
Then, if a particular coil is to be rolled to
0.024", the schedule produced by the optimizing
phase would be:
Entry Exit % computer, and achieves either a greater or
Pass Gauge Gauge Red.
1st 0.050" 0.037" 26%
2nd 0.037" 0.030" 19%
3rd 0.030" 0.025" 17%
4th 0.025" 0.024" 4%
The (iterating) optimizing routine compares
Roll Separating Force with the rated Roll
Separating Force for the mill, and adjusts the
pass reduction to achieve rated Roll Separating
Force (using the Roll Pass Schedule routine for
each iteration). It then compares the mill power
with the rated mill power and adjusts the pass
reduction or the rolling speed to use up all the
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mill power, while not exceeding the rated Roll
Separating Force.
This routine also limits the pass reduction as
required to avoid skidding or chatter, and to
keep the reduction within limits imposed by the
Production Department.
The Rationalizing Routine
To obtain a balanced rational pass reduction
schedule, which is necessary in a practical
rolling situation, the program repeats the last
four passes of the above optimized phase, but
with pass reductions adjusted to equalize
(substantially) the Roll Separating Force on
these passes. This not only helps to produce a
flat product, but will also result in a slight
increase in rate of production.
Using the above example, the rationalized
schedule might be something like:
Entry Exit %
Pass Gauge Gauge Red.
1st 0.050" 0.040" 20%
2nd 0.040" 0.033" 18%
3rd 0.033" 0.028" 15%
4th 0.028" 0.024" 14%
new schedule using the same minimum number
of passes established in the optimizing phase,
but with the last four passes balanced for Roll
Separating Force.
The Upgrading Routine
After any pass has been taken on the rolling
mill, if, for any reason, the operator does not
achieve the exit gauge specified by the
lesser gauge, the computer generates a new
optimized schedule for the remaining passes, by
running the optimizing and rationalizing phases
again when the pass is advanced.
In the above example, suppose the operator
achieved a gauge of 0.043" after the first pass
instead of 0.040". After the value 0.043" is typed
into the computer, the program might give a new
rationalized schedule:
Entry Exit %
Pass Gauge Gauge Red.
2nd 0.043" 0.035" 19%
3rd 0.035" 0.029" 17%
4th 0.029" 0.024" 17%
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 Sendzimir Mill Management System
Similarly, after the second pass, if the
operator has not achieved the expected 0.035",
and types in a value of, for instance, 0.036", the
computer might give a new rationalized
schedule:
Entry Exit % On the final pass, it is still possible for the
Pass Gauge Gauge Red.
3rd 0.036" 0.0288" 20%
4th 0.0288" 0.024" 17%
The upgrading routine is of vital importance
in any mill management program, since there
are valid reasons why the computed schedule
cannot be achieved in some instances. Possible
reasons are:
þ Excessive gauge variation in incoming
coil necessitates light first pass
reduction.
þ The material grade is different from
specified gauge.
þ The material is not fully annealed.
þ The incorrect tapers or crowns are being
used in the mill.
þ The incoming strip has a poor profile,
which requires a modified rolling
practice to achieve flat product and so
on.
Running the Program
All the programs can be selected from the
menu (DOS system) or the application can be
started automatically when the computer is
switched on (Windows systems).
In DOS systems, selection of pass schedule
program will bring up a data entry screen. After
the data is edited, the pass schedule is
computed and displayed.
In Windows systems, a list of available coils
is presented. Selection of the next coil from this
list causes the pass schedule for the next coil to
be computed when the current coil is completed.
If the exit gauge is altered by the operator at
any time during the pass, then, when the pass is
advanced (by changing the mill direction), the
computer prepares and displays a new
rationalized schedule from that point on,
highlights the next pass and sends the new exit
gauge value for the pass to the exit thickness
gauge, and the new tensions and speed to the
drive system.
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If the exit gauge is not altered during the
pass, re-scheduling is not required, and the
computer simply highlights the next pass and
sends the new gauge and tension values as
before.
operator to change the target gauge. This may
be required, for example, when the strip
thickness on the final pass is being checked and
it is found that there is a gauge calibration error.
In this case the target gauge can be offset to
eliminate the error.
Note that the operator never has to guess
intermediate gauges - they are always given by
the computer to ensure maximum reductions the
mill is capable of, together with balanced
reductions on the last several passes.
The computer will generate a gauge
deviation chart on the screen, so the operator
and management have an immediate visual
picture of the gauge performance during rolling.
This is usually done on all passes. The
computer stores all the gauge data on the final
pass (usually 1 value per ft. or 1 value per meter
of strip) for subsequent analysis and printing of
coil reports.
The operator can select gauge chart screen
or schedule screen at any time (function key
selection).
If desired, the incoming gauge data for the
first pass can be displayed and stored, enabling
reports on the quality of the incoming coil to be
generated.
Other Features of the Mill Pass
Schedule Program
þ COIL DATA file - This file is provided
with data on the coil currently being
rolled. The operator can enter the data
for each coil by responding to the
computer's prompts. This can also be
done during rolling of a previous coil
(saves time). It is also possible to
download the data from a network, or to
load the data for several coils at a time
by floppy disk, in order to save time.
þ MATERIAL DATA file - This file is
provided with data for each grade of
material to be rolled by the mill. It
contains data for all materials rolled on
the mill. A program is provided for
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 Sendzimir Mill Management System
editing this file, so that materials can be
added to the list and data modified for
any material.
þ MODOP file - This file contains the
operating parameters for the MMS
program. The file is provided to enable
the user (supervisory personnel only) to
modify the parameters. The following
parameters can be modified in order to
tune the performance of the MMS (i.e..
make schedules more aggressive or
less aggressive, increase or decrease
tension levels, etc.):
Roll Separating Force
Mill Torque
Maximum Percent Reduction
Maximum Draft
Entry & Exit Tension Rules
Maximum Tension Level
Maximum Tension Stress, etc.
It is also possible to adjust some of
these parameters on a material-by-
material basis by modifying the data in
the MATERIAL DATA file. Reduction
modifiers are also included in this file as
well as speed guidelines and the
constrained yield strength values, for
each material to be rolled.
þ Roll Bite Friction Coefficient/Rolling
Speed Relationship - The curve of this
relationship, whether for soluble oil or
mineral oil lubrication, is built in to the
program.
þ Automatic Tension Calculator Routine -
This routine calculates tensions to be
used on each pass. In principle,
maximum tension (entry and exit side) is
used for rolling of each material, within
the limits imposed by maximum coiler
tension and the allowable tension stress
for the material being rolled. Entry
tension may be reduced at heavy
gauges to increase the forward slip and
give safer rolling.
þ Viewing lateral adjustment or crown
indication settings
þ Accessing databases for selection of
coil data or coil reports.
Roll Utilization Checks
On Sendzimir ZR mills this program
remembers roll and bearing sizes currently in
the mill, gives operator allowable roll size
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ranges, checks that current roll sizes are safe,
and gives operator correct side eccentric and
lower screwdown settings.
On Z-High mills the program checks all
clearances in the cluster and determines the
correct side support spacer set or setting to be
used, based upon current roll sizes in the mill.
The program also gives correct passline settings
for Z-High mills and for 4-High and 2-High mills
Gauge Charts &
Statistical Gauge Analysis
Using an interface (such as an RS-232C link)
between mill management computer and AGC
system or thickness gauges, successive gauge
values during a pass are transmitted to the Mill
Management computer and stored on the
computer's hard disc, in the form of coil report
files.
After rolling of the coil, SPC (Statistical
Process Control) analysis can then be done if
desired either by operator selection using the
above menu, or automatically. This analysis is
done by the Mill Management software and
printed out as a coil report.
The exact SPC analysis method can be
customized to your requirements, or a
standardized program supplied. SPC analysis
can also be done on incoming coils.
If desired, the coil report files can be
transferred to a remote computer and the SPC
analysis and print out of coil reports done on this
machine rather than on the Mill Management
Computer.
Viewing & Storage of Schedules
The operator is given the option of storing
schedules during operation of the mill
management program so that he can
subsequently recall any schedule he needs to
use. The number of schedules that can be
stored is virtually unlimited (over 1000).
In general, schedule storage is only needed
in the first few weeks after startup of the MMS.
Once the operating parameters have been
defined correctly, it should no longer be
necessary to store & recall schedules.
To check if any particular schedule has been
rolled before the operator selects "viewing of
stored schedules" while the menu is displayed,
and the schedules can then be viewed
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 Sendzimir Mill Management System
according to the material, and the desired
schedule selected when running the Mill
Management program. Note that if a schedule is
recalled and displayed, and the operator misses
a gauge on any pass, the Mill Management
computer will reschedule the remaining passes
as required. The Windows version provides for
automatic sorting of stored schedules.
On-Line Operation -
Integration with Other Systems
Without the interfaces, although the MMS
Computer display informs the operator the
correct settings, he has to set the values
manually on the respective system. This makes
more work for the operator, so is not too
effective. For this reason, nearly all systems
today are "on-line".
For on-line operation interfaces are provided
(such as RS 232C links) between the MMS
computer and the AGC system and mill drive
system, the MMS computer operates "on-line"
and can provide the function of supervising the
entire mill operation. It will then send command
signals:
þ to the AGC system to set the gauge on
each pass
þ to the mill drive system to set the speed
and tensions on every pass
It will also plot gauge deviation charts and
store raw gauge data in the form of coil report
files.
It is also possible for the system to adapt
itself to the characteristics of the material being
rolled in order to refine the optimization. If mill
power, RSF, speed and tension values can be
obtained by the system (for example via analog
or serial interface from the mill drive system) the
system will compare these with theoretical
values and update the resistance to deformation
curve for the material being rolled accordingly.
Such adaptation, in order to avoid the effects
of short-term scatter, is performed slowly, with
measurements averaged over a large number of
coils. It is also possible to provide for
supervision by not updating the curve until the
MMS supervisor approves.
The MMS computer would also normally
sense when the operator changes mill direction
on the mill desk, and will advance the pass
accordingly (i.e. set thickness gauges, and send
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new speed and tension values to the mill drive
system).
For digital drive systems serial links are
usually provided between the MMS computer
and the drive. For analog drive systems the
MMS computer incorporates analog I/O boards,
and can send the necessary reference voltages
to the drive to set speed and tensions.
Network Operation
Systems have been supplied which operate
on networks - this enables uploading and
downloading of data to the MMS computer.
For example coil data can be entered on the
production control department computer and the
operator's selection of a coil number at the mill
will automatically load the required data (such as
material, width & gauges) into the MMS
program. Furthermore, the coil report files
generated by the MMS can be immediately
accessed on the quality control department
computer.
Because the raw gauge data (for example
one value of strip thickness per meter for the
entire length of the finished coil) is stored in the
coil report, the optimum end trim length can be
determined by quality control dept. using our
SPC software. This software allows the coil ends
to be "trimmed" and the gauge chart and SPC
analysis to be displayed (or printed) for the
"trimmed" coil.
The MMS computer can either be located on
a PC network, or on a VAX network, using
standard hardware and software (Pathworks)
supplied by DEC.
The normal arrangement is to have a
keyboard and monitor for the MMS computer
located at the rolling mill. However, the keyboard
and monitor can be completely eliminated in
cases where the mill operator uses a single VAX
terminal at the mill. In these cases, the supplier
of the software for the VAX system would have
to supply the software for data entry and pass
schedule display (we would provide PC source
code to this supplier).
Another approach is to use a PC running
"WINDOWS" or "OS/2" as the operator interface
for AGC or drive system, and to run the MMS
software on this PC.
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 Sendzimir Mill Management System

Mill Management System User List

Stand
Customer Mill Type Alone On-Line
1 Allegheny Ludlum Steel Co., Wallingford, CT USA ZR 33-26 X (1986)
2 Allegheny Ludlum Steel Co., Wallingford, CT USA ZR 23-25 X (1986)
3 Allegheny Ludlum Steel Co., Lockport, NY USA ZR 33-12 X (1986)
4 Avesta AB, Avesta, Sweden ZR 618A-85 X (1987) X (1992)
5 Washington Steel Corp., Washington, PA USA ZR 22-42 X (1987)
6 Washington Steel Corp., Washington, PA USA ZR 22-49 X (1987)
7 American Brass Co., Buffalo, NY USA ZR 67-30 X (1987)
8 United Aluminum Co., North Haven, CT USA ZR 23WF-37 X (1987) X (1991)
9 United Aluminum, Co., North Haven, CT USA ZR 24-18 X (1988) X (1991)
10 Lee Steel Strip Co., Sheffield, UK ZR 66-20 X (1987)
11 Brinsworth Strip Mills, Rotherham, UK ZR 64-12 X (1988)
12 Avon Cycles, Ludhiana, Punjab, India ZR 66-17 X (1988)
13 Comet Steel, Nanded, Maharashtra, India ZR 22B-50 X (1990)
14 Lee Steel Strip Co., Sheffield, UK ZR 23-19 X (1990)
15 Chicago Steel, East Chicago, IN USA 4-High X (1990)
16 Lee Steel Strip Co., Sheffield, UK ZR 33-21 X (1991)
17 Allegheny Ludlum, Vandergrift, PA USA ZR 22B-52 X (1991)
18 Sipta Coated Steels Ltd., Nanded, Maharashtra, India ZR 22B-50 X (1991)
19 Him Ispat Steel Co., Pathankot, India ZR 22B-50 X (1991)
20 Avon Cycle, Ludhiana, India 4-High X (1991)
21 Titanium Metals Corp., Toronto, OH USA ZR 22BB-50 X (1991)
22 Uttam Galva, Maharashtra, India ZR 22B-50 X (1991)
23 Jawahar Metal #2, Uttar Pradesh, India ZR 22B-50 X (1991)
24 Criterion Metals, Attleboro, MA USA 4-High X (1992)
25 Texas Instruments, Attleboro, MA USA ZR 16-8½ X (1992)
26 Special Steels Ltd., Tarapur, India ZR 612A-50 X (1992)
27 Guangzhou, China 4-High, #1 X (1992)
28 Guangzhou, China 4-High, #2 X (1992)
29 Allegheny Ludlum, Wallingford CT USA ZR 33-26 X (1992)
30 Allegheny Ludlum, Wallingford, CT USA ZR 23-25 X (1992)
21 Allegheny Ludlum, Waterbury, CT USA ZR 23SC-25, #2 X (1992)
32 Tung Mung, Taiwan ZR 21BB-54, #1 X (1992)
33 Tung Mung, Taiwan ZR 21BB-54, #2 X (1992)
34 Sam Yang Metals, Korea ZR 21-44 X (1993)
35 Coshocton Stainless Div. Armco, Coshocton, OH USA 4-High X (1993)
36 Steel Technologies, Canton, Michigan ZR 611A-44 X (1993)
37 Teledyne Rodney Metals, New Bedford, MA USA ZR 22-42 X (1993)
38 Worthington Steel Co., Columbus, OH 4-High X (1993)
39 Washington Steel Co., Massillon, OH USA ZR 22-49 X (1993)
40 Columbus Joint Venture, Middelburg, South Africa ZR 613A-63 X (1994)
41 Steel Tubes of India, Dewas, Indore, India 4-High X (1994)
42 Uttam Steel, Ltd., Khopoli, India 6-High X (1994)
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Mill Management System User List
Stand
Customer Mill Type Alone On-Line
43 Lee Steel Strip, Ltd., Sheffield, England Sundwig 20-High X (1995)
44 Raymond Steel, Ltd., Thane, Maharashtra, India 4-High X (1995)
45 Lee Steel Strip, Ltd., Sheffield, England ZR 23-19, #2 X (1995)
46 Foshan Precision, Guano Dono, China 4-High X (1995)
47 Special Steels Ltd., Navsari, India 4-High X (1996)
48 Avery Cycles Ltd., Ludhiana, India 4-High X (1996)
49 Jindal Iron & Steel Co., Tarapur, India 6-High X (1996)
50 Tube Products of India, Madras, India 6-High X (1996)
51 United Aluminum, North Haven, CT, USA ZR 23WF-37 upgraded to X (1996)
Windows
52 CSN, Volta Redonda, Brazil 4-High X (1996)
53 Lukens Inc., Washington, PA USA #3 Mill ZR 22-42 upgraded to X (1996)
Windows
54 P.T. Badja Ind., Indonesia 4-High X (1996)
55 Shanghai Stal #1 Mill, China ZR 33C-27 X (1997)
56 Shanghai Stal #2 Mill, China ZR 23SC-26 X (1997)
57 Precision Specialty Metals, CA, USA ZR 22WFT-52 X (1997)
58 Special Metals (Inco) IN, USA ZR 22WF-52 X (1998)
59 Jupiter Aluminum IN, USA ZR 67-32 X (1999)
60 Steel Technologies KY, USA ZR 24C-15 X (2000)

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