Revolutionizing the Wheeled Mill: A Transformation to Efficient and Accurate Grinding
The wheeled mill, an essential machine in various industries, has undergone a significant transformation to improve its efficiency, accuracy, and stability. The old system, relying on 8088 and 8086 central processors, was plagued by limitations, including the lack of automatic roller deviation compensation, restricted data processing, and high maintenance costs. These issues hindered the production of high-quality products and hampered the performance of the mill. To address these challenges, a comprehensive renovation was undertaken, introducing cutting-edge technology and advanced features.
Renovation Contents: Innovative Solutions for Enhanced Performance
The overhaul focused on the following areas: 1) upgrading the CNC system, 2) optimizing the measurement system, 3) recovering the precision of bed and rail surfaces, 4) enhancing the central framework, 5) balancing grinding wheels, and 6) adding new features.
CNC System Revamp
The new CNC system features advanced automation capabilities, including:
- Fully automatic grinding cycles and measurement
- Automatic fault detection and correction
- Multi-interface monitoring, including Chinese-language support
- Redundant disk system and automatic redundation technology for enhanced stability
- Online diagnostic system for operator instructions and explanations
These updates enable the CNC system to perform a range of automatic functions, including:
- Referencing each axis
- Bear calibration centering
- Measurement arm calibration
- Automatic roller compensation deviation
- Constant current calibration
- Speed compensation for grinding wheels
- Automatic quantification of grinding and diameter
Measurement System Upgrade
The revamped measurement system has been redesigned to provide more accurate and efficient measurements. The new CP-type measurement arm features a calibration ring suitable for grinding hot rollers, enabling the measurement of X1 axis, X axis, and X1T2 feet and X1T1 and X1T2 measurement heads. The measurement axes are driven by servo-motors, allowing for rapid and precise movement.
Recovering Precision of Bed and Rail Surfaces
The original guide rails and drive trees have been accurately repaired and updated, ensuring precise alignment and motion. The system is now equipped with a new guide rail and drive tree, providing a more robust and stable performance.
Central Framework Revamp
The central framework has been preserved and updated to maintain its precision. The original probe electric proxy mechanism has been replaced with a manual depth rule, improving speed and accuracy. The main mechanical central positioning device has been improved with a high-speed automatic eccentricity device, reducing eccentricity and enhancing grinding efficiency.
Balancing Grinding Wheels
The traditional method of manual balance adjustment has been replaced with a new balance system featuring a dynamic balance device and a M5100 balance. This enables automatic balancing of grinders at any time, ensuring reliability and precision.
Adding New Features
To leverage IT advancements, the renewed system has been integrated with:
- Centralized Crusher Control System: A centralized control room provides remote operator panels and industrial surveillance systems, enabling operators to monitor and control multiple grinders from a single location.
- Crushing Data Acquisition System: A grinding data acquisition server, running Windows 2000 Server and RMS Waldrich software, analyzes and manages roll data, facilitates data exchange with CNC systems, and enables level roll management.
- Remote Diagnostic System: A new remote diagnostic device has been added, allowing for real-time monitoring and issue resolution.
- Roller Failure Detection: A Foucault Lismar current fault detection system has been integrated, enabling fault detection and management.
Conclusion:
The comprehensive renovation of the wheeled mill has resulted in a significant improvement in accuracy, efficiency, and stability. The enhanced systems have reduced human resource investment, improved system reliability, and facilitated maintenance. With its cutting-edge features and advanced technology, the wheeled mill is now poised to deliver high-quality products and satisfaction.
