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At present, the trend of high-speed, wide-width and large-volume rolling of aluminum foil rolling mills is gradually updating the original rolling mill design concept, especially in terms of rolling mill speed and production efficiency. Therefore, the challenge of the new high-performance aluminum foil mill is to solve these problems and improve the limit parameters of the mill performance.
VAI's VAntage process control system sets a standard for the foil shape and thickness tolerances of the foil. The success of this system is that it largely solves the limitations of product quality factors on the speed and output of the mill. Emphasis is placed on mechanical components such as ironing rolls, strip drying systems, and foil feeding systems. Based on the deep processing technology and design technology of household aluminum foil, VAI has developed the mature design technology of the above key components, which is included in the technology package software from VAIFoil.
With the increase of the rolling speed of the aluminum foil, the ironing roller increases the production loss and the difficulty of the next processing process due to the air entering and causing the coil to be folded and unwound during the aluminum foil winding process. In order to avoid the above phenomenon, the usual practice is to limit the rolling speed of the strip, and as a result, the production capacity of the rolling mill cannot be fully exerted.
To solve this problem, VAI analyzed the process of crimping and ironing to find out the key factors. VAIFoil's design includes a hollow balance roller with good dynamic balance, low inertia, oil-lubricated roller bearings and manual controls. There are three factors that need to be considered in the middle: - the position of the ironing roller on the coil; - how to maintain a constant ironing pressure; - the surface of the ironing roller coating material.
Regarding the position of the ironing roller, it is mainly required that the contact surface of the roller and the foil can be maintained just after the cutting point of the foil and the reel during the winding process, so as to ensure that the ironing roller can effectively extrude the air. The VAI design successfully satisfies this requirement by fully considering the relative position of the design roll to avoid the danger of the operator touching the inlet and outlet sides.
The precise control of the ironing pressure is very important for the quality of the finished roll. For this, VAI developed a software package consisting of a servo valve system and a control algorithm and integrated it into the VAn-tage system. Independent closed-loop control system on both the operating and drive sides and sufficient cylinder pressure to ensure constant ironing pressure.
Another key factor affecting the performance of the ironing roller is the coating material used to screed the surface of the roller. The material is required to withstand the corrosion resistance of the rolling oil, has a suitable surface hardness to avoid bumps, has a certain damping effect and the ability to suck the foil. Steel rolls are advantageous for thick gauge strips, which can be quickly flattened and reduced on the web. However, such rolls have a high degree of vibration and high noise. In contrast, polyurethane has a certain attraction to the strip and also has a certain damping effect. From the application effect of most aluminum foil rolling mills, in addition to the use of steel rolls for the production of thick-scale products, VAI is generally recommended to use rubber-coated rolls. In most cases, due to the wide range of specifications for mill design and production, it should be considered that steel rolls and rubberized rolls can be interchanged.
The strip drying system removes the residual coolant on the surface of the strip after rolling to ensure that the surface is clean and dry. It is an important indicator to measure the quality of the strip, which is of great significance for improving the yield and yield of the strip. Tests have shown that the strip is very dry when it leaves the roll gap. Therefore, VAI's ALUVanceStrip's strip drying system pays more attention to how to prevent coolant contamination before removing it. Based on this idea, the ALUVance system provides a complete drying system by integrating various factors.
Support Roller Roller: Prevents the coolant on the inlet side of the roll from being transferred to the outlet side in the direction of the support roll. A baffle is provided on both the upper and lower sides of the exit and inlet sides of the mill, which is achieved by pressing a "guard" on the roll surface of the support roll. The guard plate is placed between the upper and lower support roller chocks and can be rotated by a rotating shaft. The device allows for accurate adjustments outside the line, and the force gauge can be used to precisely set the pressing force of the slab to ensure optimal cleaning and long slab life. The roller cleaner also helps to clean up the debris.
Purge nozzle: Located on the exit side of the mill, facing the upper work roll and the roll gap between the upper support roll and the work roll, a lateral air flow is generated to effectively blow the rolling oil to both sides of the mill. In particular, the “cross†nozzle is selected for the area between the rolls, and two rows of flat nozzles are selected for the work rolls. The spray effect of the nozzle depends on the correct angle setting and air flow rate. These parameters are all obtained empirically. All nozzle devices are fixed to the bearing housing for off-line adjustment, and air enters the nozzle through the housing automatic coupling of the upper work roll.
Rolling mill splash guard: The simplest device to prevent the coolant from coming out is a reliable guarantee to obtain the maximum drying of the strip surface. The outlet side splash guard is fixed on the strip with a pin, which is easy to remove quickly. When the mill is maintained and the debris is cleaned, the oil curtain placed at the roll neck can reduce the oil between the rollers beyond the width of the strip. The outflow, the auxiliary oil shield on the upper roller clearer ensures that the coolant removed by the roller clearer will not be lost on the roller. All of the splash guards on the upper part of the strip are angled and have suitable flow channels on them to allow the coolant to collect along the flow channels to the sides of the mill (outer end of the strip).
Optimized injection control: This is not a direct component of the ALUVance strip drying system, but an important factor in reducing the amount of coolant that is carried out throughout the mill. In short, the less the coolant is used, the easier it is to control the surface of the strip. The VAI analysis of the work roll cooling mechanism shows that the size of the spray area is the most important for the cooling effect. Its effect is 10 times higher than the coolant flow rate. Therefore, VAI's rich processing experience shows that optimizing the injection method and selecting the appropriate nozzle can significantly reduce the coolant flow without affecting the cooling effect and the shape of the foil.
The foil threading system maximizes working time and is very important to achieve production targets. One of the most critical factors is how to reduce the wearing time. As the width of the strip increases, the difficulty of wearing the strip increases, especially for the thin gauge foil. In the technical solution designed by VAIFoil, for the rolling process of all foils with a thickness of less than 0.7 mm, VAI has developed a foil feeding system, which is to set up a floating platform on the exit side of the rolling mill to simplify and speed up the wearing process.
At the same time as the tensioning roller is set, the foil feeding system uses the suction cup to clamp the strip when the thick gauge foil (thickness > 0.1 mm) is worn, and the VAI "BlownWing" for the thin gauge foil of less than 0.1 mm. The device feeds the tape.
BlownWing is a specially developed corrugated plate with a nozzle that produces a vacuum to absorb thin gauge foil strips. Based on the Bernoulli principle, the speed is increased and the pressure is reduced. This unit has an automatic adjustment function for the foil and the BlownWing spacing. Once wrinkled, the foil can also open itself to a certain extent by virtue of its own stiffness. When the end of the foil protrudes from the table by 250 mm, it can be reliably delivered to the roll bite.
When the belt is ready to be worn, the tensioning roller of the inlet is in the upper limit position, and the wearing brackets arranged on both sides of the tensioning roller frame are arranged in an adjusted position, and the belt rack is fastened to the two sides of the aluminum foil strip. There is a support plate in the middle to support the strip in the width direction. The bracket is guided forward by a drive chain along the guide direction, and the unwinder is also unwinded simultaneously. After the inlet tension is established, the belt holder is retracted and the tension roller is pressed down to the rolling position.
This system has been successfully applied to three-roll and four-roll compacted aluminum foil mill fronts with trimming devices, which produce quite good dry and wet foil products.
Breakthrough in the wearing and take-up design of the world manufacturer VAI foil rolling mill
Based on extensive experience in the manufacture of aluminum foil rolling mills, VAI, a world-renowned manufacturer of aluminum foil rolling mills, recently developed a process technology to solve the problem of the wearing and winding of aluminum foil rolling mills. The latest VAIFoil mill design significantly improves yield, throughput and productivity. This new technology is not only for new mills manufactured by VAI, but also for many existing mills that can be retrofitted with this latest technology.