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Please
contact us if we can answer any questions regarding our technology development and
capabilities. Read about our development of a Field Programmable Grid Array (FPGA) motion
control system.
A New Architecture for Automatic Gauge Control Systems
Automatic Gauge Control
Elongation Control
Statistical Process Control
Automatic Gauge Control - AGC
I2S has designed, manufactured, installed and started up well over one hundred computerized
Automatic Gauge Control Systems based on the mass flow equation. In the words of our
customers, these systems are “outstanding performers.” I2S, LLC has installed AGC on one way
mills, reversing mills, tandem mills, Two-Highs, ST 20 High Cluster Mills and combination
Four-High / Z-High Mills.
The I2S, LLC Computerized AGC System has two modes of operation:
1. Computerized adaptive feed forward control using the mill screwdown as means of
correction also referred to as a "Mass Flow".
2. "After the fact" control using only the exit gauge
The Mass Flow Method of Gauge Control The basic adaptive feed forward system uses the
following inputs:
Entry Thickness Gauge
Exit Thickness Gauge
Entry Pulse Generator
Exit Pulse Generator
Separating Force
Mill Modulus
The basis for the mass flow gauge control is that the volume of metal that is entering the mill is
equal to the volume of metal leaving it. The basic equation is: Lin x Tin x Win = Lout xTout x
Wout. The philosophy is to compute the thickness of the strip leaving the roll bite in the smallest
practical increment of strip travel and issue proportional corrections to the mill screwdown. By
utilizing this robust mathematical model, thickness control is optimized even while running
slowly and during speed changes.
The exit thickness gauge is used as a master reference, and this gauge is read and averaged every
time the primary loop is read (Volume in = Volume out). If the primary loop is not maintaining
the exact desired thickness, it is adjusted slightly to bring the average output strip thickness
deviation to zero. This cycle of events is repeated on a continuous basis and system adjustments
are made as necessary.
This system is used on the loading pass from the payoff, when entry side pulse tach or strip
thickness gauge cannot be used.
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Elongation Control
The I2S elongation control system
acquires elongation comparison signals by
means of two high resolution tachometers
(entry & exit). A tach termination board
processes the signals into the tach
interface board contained in the industrial
IBM compatible computer.
The I2S elongation control system continuously monitors the actual elongation to make sure you
achieve your customers' specifications, consistently. For more information on applying our
elongation technology to your company's particular production, please contact a representative in
our sales department.
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Statistical Process Control - SPC
Why SPC? Prevention vs. Detection
A traditional approach to manufacturing is to depend on production to make the product and on
quality control to inspect the final product and screen out items not meeting specifications. In
administrative situations, work is often checked and rechecked in efforts to catch errors. This is
wasteful because it allows time and materials to be invested in products or services that are not
always useable. After-the-fact inspection is uneconomical; it is expensive and unreliable, and
wasteful production has already occurred. (*)
A prevention strategy sounds sensible -- even obvious -- to most people. It is easily captured in
such slogans as, “Do it right the first time.” However, this kind of cheerleading is not enough.
What is required is an understanding of the elements of a Statistical Process Control system. (*)
The I2S, LLC SPC data gathering system is largely based on the methods and interpretations as
outlined in the Ford Motor Company’s publication listed in the footnote below.
(*) Taken from the Ford Motor Company’s booklet number 80-01-251 “Continuing Process
Control and Process Capability Improvement” September 1985.
While the mill is running we also display range and average charts on the screen, a kind of ”SPC
on the fly.” These charts are constantly being updated while the strip is being rolled and
provides instant feedback to the operator on how the gauge quality is being maintained. There
are also screens on the computer that enable the setting of specification limits, full scale ranging
for the charts and other setup information.
At I2S, LLC we do not stop our quality reporting with these SPC charts, we also provide other
optional methods of inspecting gauge control quality.
It is a crucial part of business today that for every process control system there is a flexible, easy
to use, quality control system that can be used to monitor performance. With the I2S, LLC
automatic gauge control coupled with the SPC/QC reporting package, control and verification go
hand in hand.
Products:
I2S Designs, Manufactures, Revamps, Installs, Commissions & Services Cold Rolling Mills
and Ancilliary Equipment. Mill Types
2HI
4HI
Bonding
20-Hi C
Mill
Tandem
Temper
Tube an
Wire Fl
Non-Contact G
Systems
Gamma
X-Ray G
Gauge controls, gauge set up parameters, and calibration are all accessed through the
touchscreen and can be saved to disk. All system readouts can be displayed in English units or
Metric.
All controls are accessed through the main menu. Our new Alloy Screen allows the operator to
associate the material composition number to the more familiar name that is used for the
material. Once entered, the alloy is then selected by its desired name and the internal
information is automatically entered into the computer system. Set gauge, source on/off,
standardization, as well as an electronic strip chart display simplifies calibration and operation of
the gauge. The I2S, LLC non-contact gamma gauge is the finest available.
Our gauge system has never been easier to operate or set up. Complete system knowledge including operation,
calibration, troubleshooting, and maintenance can be attained through a minimal amount of instruction.
The I2S gamma gauge has been designed for the rugged industrial mill environment and complies with all Unit
Nuclear Regulatory Commission and international standards for gauge safety.
At I2S, LLC, we are continuously researching and developing the latest in technology to keep you at the forefr
today’s high-tech metals processing industry.
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X-Ray Gauges
Do you need to measure something as thin as newsprint? Something as thick as an inch of steel? Do you need
gauge to be non contact? Fast? Reliable? Able to hold tolerance to an accuracy of 0.1%?
No problem. The I2S X-Ray Gauging System does all this, and more. We are offering a completely new X-Ray
design with many advantages:
Ion Chamber has excellent stability and long life Rugged, simple
construction.
Significantly improved temperature stability over photomultiplier
systems.
Bullet-proof design.
New high frequency X-Ray generator offers quick response, low
ripple and high stability
Fast alloy compensation ability
Digital, Pentium based, touch screen control
Embedded real-time signal processing hardware integrated with
Windows 2000/XP
Supervisory control Remote I/O control of generator subsystem
resulting in reduced wiring
Constructed from commercial off-the-shelf (COTS) components
Further
enhances
the I2S Single Source Responsibility!
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