Condition Monitoring Solutions for Cold Rolling and Tandem Mills. Ing. Marco Aietti Schaeffler Italia S.r.l.

Transcription

1 Condition Monitoring Solutions for Cold Rolling and Tandem Mills Ing. Marco Aietti Schaeffler Italia S.r.l.

2 2 Schaeffler Group - Expertise in Maintenance

3 Typical amage Progress of a Bearing machine condition change in state Early recognition of the damage through Condition Monitoring Vibration Particles Noises Heat Smoke time lead time Minutes ays weeks Month 3

4 Mounting and Monitoring of Roller Bearings Monitoring by Means of Spectrographic Analysis bearing damage misalignment gearmesh time signal unbalance With the Fast Fourier Transformation (FFT) the frequency spectrum of the time signal of an oscillation is calculated. Thus the characteristic frequency ranges can be easily analyzed. Spectrum Frequency 4

5 Bearing defect frequencies Mounting and Monitoring of Roller Bearings Ball Pass Frequency Outer Race (BPFO) Ball Pass Frequency Inner Race (BPFI) Ball Spin Frequency (BSF) Fundamental Train Frequency (Fixed Outer Ring) Fundamental Train Frequency (Fixed Inner Ring) f f z a n W T cos α cos 1 z f 2 1 f T W n i 2 cos T W W T n w f f f f k n W T cos f f k n W T cos w : Roller iameter t : Pitch Circle iameter : Contact Angle z: Number of Rollers f n : Rotary Speed BPFO + BPFI = z 5

6 Introduction Application Examples: Service Solutions for Cold and Tandem Mills Coiler Gearbox Condition Monitoring Bearings and Gears Boroscopy-Service Online Oil particle analysis Chatter Mark etection Support Roll Bearings Mounting Service FAG Heating device Condition Monitoring* Reconditioning** Pinion Stand Gearbox Condition Monitoring Bearings and Gears Borescopy-Service Reconditioning Work Roll Bearings Mounting-Service Condition Monitoring Tensiometer- & Consolidation rolls Condition Monitoring * restricted for plain bearings ** only for cylindrical roller bearings 6

7 Introduction Condition Monitoring of Roll Bearings in Cold Rolling and Tandem Mills Typical cause of failures for rolling bearings in rolling mills are e.g. vertical and / or horizontal misalignment of the working and support rollers, wear of the mounting bracket and increased axial forces during the rolling process. uring the rolling process the bearings of the work-, support-, tensiometer-, and consolidation rolls can be monitored A condition monitoring system, based on vibration measurement, is a tested and verified solution to avoid unplanned downtime. 7

8 Condition Monitoring of Roll Bearings in Cold Rolling and Tandem Mills 4-High Sensor Positions: Work- and Support Rolls Schaeffler's tried-and-tested solution is to mount the sensors directly on the rolling stand. The vibrations are transmitted from the chocks to the rollingstand and are recorded by the sensors. Hence, the sensors do not influence the installation and removal of the rolls, The measurement is validated using the motor speed and load signals. Sensors: 1 Accelerometer on frame per chock unit Measurement Hardware 1 FAG TECT X1S 8

9 Condition Monitoring of Roll Bearings in Cold Rolling and Tandem Mills 6-High Sensor Positions: Work-, Intermediated and Support Rolls Schaeffler's tried-and-tested solution is to mount the sensors directly on the rolling stand. The vibrations are transmitted from the chocks to the rollingstand and are recorded by the sensors. Hence, the sensors do not influence the installation and removal of the rolls, The measurement is validated using the motor speed and load signals. Sensors: 4 Accelerometer on frame, each on drive and non-drive side Measurement Hardware 1 FAG TECT X1S per stand 9

10 Condition Monitoring of Roll Bearings in Cold Rolling and Tandem Mills References: Condition Monitoring on Rolling Mills References 10 Application Location Work rolls of a 7 stand finishing mill Bochum Work rolls & support rolls of 2 Steckel mills Casablanca Work rolls of 4-High hot rolling mill Székesfehérvár Breast rolls of a roughing mill Salzgitter riving rolls coiler hot rolling mill Salzgitter Support rolls of a 4-High hot rolling mill Lower Saxony Support rolls of two 4-High cold rolling mills udelange Shape- & Tensiometer rolls of a tandem mill ortmund Work & support rolls of three cold rolling mills Székesfehérvár Flatness measuring rolls of cold rolling mill Eisenhüttenstadt Back-up rolls of a 20-High Sendzimir mill illenburg Consolidation rolls of a 20-High Sendzimir mill üsseldorf Foil finishing mill Grevenbroich Foil finishing mill Eppstein Smoothing Rolls of 4-High aluminum mill Göttingen Work rolls of 4-High cold rolling Gelsenkirchen

11 Introduction Chatter Mark etection Resonance areas In addition to condition monitoring solutions for critical components, the Schaeffler Group also offers reliable solutions for controlling and maintaining product quality. Mill vibrations and the resulting chatter marks reduce productivity because they limit the strip speed and cause markings on the strips (chatter marks). These reduce the product quality. uring the chatter mark monitoring, the individual resonance areas of each mill stand are continuously monitored with a FAG TECT X1S. The plant operator recognizes the critical rolling speeds via an online display of the vibration levels in the control room and avoids these. 11

12 Chatter Mark etection Sensor Positions for Chatter Mark etection Sensors: 2 Accelerometers per rolling stand (A/B-side) Measurement hardware 1 FAG TECT X1S per rolling stand 2x Connection of the alarm outputs to the PLC * / Visualization via analog 4-20mA signal * * Please pay attention to the EC machinery directive 12

13 Chatter Mark etection References: Chatter Mark etection References 13 Application Location 5 stand tandem mill uisburg 5 stand tandem mill ortmund Skin pass mill Eisenhüttenstadt Cold rolling mill Eisenhüttenstadt 20-High Sendzimir mill Isbergues 2 cold rolling mills Vanderbijlpark Cold rolling mill Neuwied 3 aluminum cold rolling mills Székesfehérvár Aluminum cold rolling mill Göttingen Aluminum cold rolling mill Grevenbroich Aluminum cold rolling mill Ohle

14 Condition Monitoring of Gearboxes Introduction f.l.t.r: Pinion stand gearbox, damaged feather key, inner race damage (borescopy) By measuring the vibration on the gearbox, the current condition of the installed rolling bearings and gears can be determined and constantly monitored. In addition to the vibration measurement, an oil particle counter can provide information about the current wear of the gears (in oil lubricated gearboxes). The FAG WearebrisCheck is installed via a bypass of the oil circulation lubrication system and monitors the particle-count, classification and weight of the passing metallic and nonmetallic particles in the oil. If the pre-determined alarm level is exceeded, an external alarm can be triggered that saves important time. Especially in case of a sudden damage (e.g. teeth breaking), it is possible to prevent expensive consequential damages. 14

15 Condition Monitoring of Gearboxes Sensor Positions on the Pinion Stand Gearboxes On each pinion stand gearbox, at least 3 accelerometers have to be installed (1 x input shaft, 2 x output shaft). In order to validate the measurement, the motor speed and load are being recorded. Sensors: 3 Accelerometers optional: Oil particle counter FAG Wear ebris Check 2 characteristic values: particles per minute particle mass per hour Measurement Hardware 1 FAG TECT X1s

16 Condition Monitoring on Gearboxes References: Gearbox Monitoring (Extract) 16 Application Location Reducing & pinion Gearboxes of 3 roughing mills Temirtau Gearbox aluminum hot rolling mill Koblenz Pinion gearboxes of 5 stand tandem mill uisburg Pinion gearboxes of 5 stand tandem mill ortmund Pinion gearboxes of 2 cold rolling mills Neuss Pinion gearbox reversing mill Skinningrove Gearbox of a 4-High cold rolling mill üsseldorf Gearbox of a 20-High Sendzimir mill üsseldorf Gearbox of a tube pieling machine üsseldorf 2 worm gears of a 12-High cold rolling mill Altena Gearbox of a sinking mill Altena

17 Condition Monitoring Why Schaeffler? Competence from a single source! The customer benefits from the specific industry know-how of the vibration experts. At the same time, the customer has access to the knowledge of a world-leading bearing manufacturer and thus benefits from application-specific products and services from a single source. Reliable Remote Service Certified service engineers (according to ISO18436 Cat. II III) Over 500 installations are permanently monitored Service Centers in Australia, Germany and USA Fast reaction times Competent support via phone or irect linking to resources of the Schaeffler Group In-House Competence (Schaeffler) for: amage analysis Corrective maintenance (balancing, alignment) Bearing assembly / disassembly Lubrication / Lubrication automation Consulting by the Schaeffler application technology 17

18 18 Thank you