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S continuously strives to improve the technology of the metals processing industry.

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.

The “After the Fact” Method of Gauge Control


The other mode of gauge control is the exit feedback method. This is called “After the Fact”, on
legacy mills "GB-
100". This mode
uses only the exit
gauge for making
corrections to the
screwdown.  One
tach, either driven
off the exit side of
the mill, or the mill
tach (whichever is
available), is used
to initiate the
corrections.  It is
based on the
assumption that
the thickness of the
metal in the roll
gap is the same as
the thickness at the
gauge.  It reads the
gauge over a short interval and averages these readings to get a better idea of the thickness of the
metal at the roll gap.  If this averaged thickness is different than the desired thickness, the mill
screwdown is issued a command to move a proportional amount based on mill modulus and
separating force.

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.

I2S' elongation software then analyzes the


tach signals. By comparing the measured
"length in" with the measured "length out"
of the strip, the actual elongation is
calculated. If the specified elongation is
not being achieved, the screwdown
control board sends movement commands
to the hydraulic screwdown system.
Adjustments in the screwdown force increase or decrease the elongation to match the specified
elongation setpoint value entered by your operator.

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.

Overview of the SPC/QC System


We sample the gauge deviations from the exit gauge and use them to generate range and average
charts.  Standard deviations and Cpk values are also calculated.

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

Two High Mills (2HI) for specialty applications


I2S, LLC can supply 2 High mills for specialty applications.
These mills are occasionally a better solution than 4 High mills for light reduction and
camber control for in-line use such as roll forming and stamping operations.
Heavy reduction of plate material is another area where 2 High mills, with their large
roll bite, are often used. Lastly, we provide many 2 High mills for skin pass / surface
conditioning applications. Please refer to our section on Temper / Skin Pass Mills for
more information.
 

Four high mills are probably the most common type of


mill
and are used throughout the ferrous and non-ferrous
metal industries. Four highs can be used for heavy
gauge "breakdown" rolling, for relatively thin gauge
finish rolling and for temper / skin pass rolling.
Four highs
Fourcan be Mills
High supplied forfor
(4HI) oneallway operation, for
applications
reversing operation or in multiples for tandem
operation
Bonding Mills for cladding and inlay applications
At I2S we have designed and manufactured 4 highs
ranging in size from 2" & 5.25" x 8" to 21" & 49" x
108", speeds from 10 FPM to 3,300 FPM and
separating forces from 50,000 lbs to 7,000,000 lbs.
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I2S has designed and supplied bonding mills for cladding an
assortment of ferrous and non-ferrous metals. Clad materials
range from multiple "full strip width" layers such as used for
coin stock to multiple inlayed strips used in the precision
electronics industry.
I2S bonding mill lines include multiple uncoilers, strip clean
equipment, take-up reels, etc.
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20 Hi Cluster Mills (ZR Mill)


20HI or "ZR" Mills (20 High Cluster Mills) to meet every requirement!
I2S has developed a line of very successful 20 Hi Cluster- monoblock
20HI Mills for accurate thin gauge production. These mills are also the
best choice for heavy reduction of harder
materials such as stainless steel due to the rigid
housing design and work roll support within the
cluster.
Aside from I2S' own design in various sizes and
widths, I2S also offers licensed versions of the
T. Sendzimir, Inc. ZR Mill. Please take a
moment to review some of the features that
contribute to this superior design as well as a
few featured projects which are available for download in PDF format
from the link on this page.
 
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Tandem Mills
New and Modernized Multi-stand Mills
I2S has designed and supplied new Tandem Mills and equipment modernizations in many configurations.
Those Mills feature the I2S patented hydraulic screwdown system, AGC, drive systems, inter-stand tension c
and mechanical equipment innovations.
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Temper Mills
Temper Mills - Stand Alone or In-Line Applications.
Temper mills are an integral part of the processing of metal.
Recent trends have caused an increase in the use of Temper Mills
as part of processing lines. I2S has provided Temper/Skin Pass
Mills for tension leveling lines, galvanizing lines, cut-to-length
lines and stamping/roll form lines.
Those Mills are designed to produce coils with superior flatness
and surface quality, reducing coil spring-back for downstream
operations and therefore increasing the value of the material to
the end user.
 
 
B
 
Tube and Pipe Mills
I2S provides patented in-line gauge and camber controls for today's high speed, high precision, welded tube,
forming, and stamping lines.
Important features related to the I2S Tube and Pipe Mills:
In-Line, real time, adjustment of incoming raw materials to /- 0.0005" of desired tolerance (within the desig
capacities of a given mill). Based on a maximum incoming strip thickness variation rate of 0.0005" per foot
length.
B
 
Wire Flattening and Shaping Mills
Let I2S be your source for wire flattening and shaping equipment. Flattening and shaping mills can be custom
designed for ferrous or non-ferrous products. I2S has built wire shaping lines that have incorporated as many
mill stands with speeds up to 1000 FPM. Higher speeds are available.
B
 
Non-Contact Gauging Systems
Gamma Gauges
I2S now offers the first "Mill Duty" Gamma Gauge designed
by a fully integrated mill builder, specifically for the harsh m
environment.

The new system consists of a resistive industrial touchscreen


and a Pentium computer which can be used as a Stand Alone
It can also be fully integrated into a complete mill system uti
AGC, SPC, and Programmable Logic (PLC) controls.  The o
Strip Profile feature automatically traverses the gauge across
width of the strip, detecting each edge, and graphically repro
profile of the strip thickness on the computer screen.
I2S has researched and utilized the most advanced hardware available to remove drift and noise. Our preamplif
electronics have been designed from the ground up to offer superior signal handling while withstanding the sig
shock hazards so common with rolling mills. The computer uses many of the same boards we run in our AGC
touchscreen computers thus reducing spare parts needed by our customers.
I2S has also improved all of the electronic components to take advantage of the latest advances
in opto signal processing. The gauge interface boards are all printed circuit type and designed
with quick release terminal strips for ease of installation and troubleshooting.

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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