Optical Guide Alignment Systems for Long Rolling Mills

In long rolling mills, precise guide alignment is crucial for achieving superior product quality and minimizing defects. Optical guide alignment systems from Primetals Technologies are designed to enhance accuracy, increase productivity, and reduce downtime. Our range of systems provides cutting-edge solutions for online and offline guide settings, ensuring mill operations run smoothly.

The Advanced Optics System utilizes machine vision with edge detection to provide real-time feedback, significantly increasing accuracy and repeatability in the guide and mounting bracket setup and alignment. Its intuitive, icon-driven touchscreen interface simplifies operation, while built-in tracking and accounting capabilities offer valuable insights into the guide-setting process.

The USX series, a range of leaf-type roller entry guides designed for high-speed rod mill applications in finishing stands, is highlighted below. The precision "X"-clamp mounting system allows zero-tolerance mounting, less affected by wear, and the single-point symmetrical roller adjustment offers ease of use. All aspects of this guide are designed to facilitate optimal guiding within a high-speed rod block.

Advanced Optics Systems for Roller Guide Precision

Primetals Technologies offers a range of advanced optics systems designed to enhance the precision, efficiency, and reliability of roller guide setups in long rolling mills. Engineered for both offline and online applications, these systems ensure accurate guide settings, reduce downtime, and improve product quality across various mill configurations.

Key Features of the Advanced Optics System

• Guide and bracket setting accuracy: ±0.025 mm (0.001”)
• Intuitive interface: icon-driven touchscreen
• Live edge recognition: user feedback with go/no-go confirmation
• Dual calibration: for left- and right-hand setups
• High-power LED light source: collimated for consistent illumination
• Bi-telecentric lens: ensures accurate measurements

Features of Advanced Bench Optics

• Digital templates: for precise guide settings
• Optional pin-coded user login: enhances security and accountability
• Tag printer: labels set guides for easy identification
• Built-in training material: facilitates operator training
• 5.5x magnification: provides detailed views

Features of Advanced Portable Optics

• Real-time roll cross measurement: monitors roll alignment during operation
• Automatic roll sag compensation: adjusts for roll deflection
• Wireless operation: scope and light source can be operated remotely
• Docking station: for convenient charging
• 2.8x magnification: suitable for various guide sizes

Main Benefits of the Advanced Optics System

• Enhanced accuracy: achieve guide setting accuracy to ±0.025 mm
• Improved efficiency: streamlined setup process reduces downtime
• Increased accountability: optional login and tracking functions monitor guide settings
• Simplified operation: intuitive interface reduces the learning curve
• Advanced calibration: software-based calibration ensures precise alignment
• Eliminates printed templates: digitized templates replace traditional mylar templates

Bench Optics Systems

Large Bench Optics Systems for Intermediate, Pre-Finishing, and Finishing Mills

The Large Bench Optics System is designed for the offline setting of roller guides, enabling adjustments within ±0.05 mm of the theoretical incoming stock dimensions. Compatible with various Primetals Technologies guides, including the USX finishing mill guide systems, it offers flexibility with 3x and 5x magnification lenses for detailed viewing.

Features of Large Bench Optics

• Guide setting accuracy: ±0.05 mm (0.002”)
• High optical quality: resolution of 0.028 mm (0.001”)
• Magnification options: 3x and 5x lenses
• Mylar templates: provided with passes for each product size

Small Bench Optics Systems for Rod Finishing Mills

The Small Bench Optics System is designed for accurate offline roller guide settings, achieving precision within ±0.05 mm of the theoretical incoming stock dimensions. Compatible with the USX finishing mill guide systems and other configurations, it features a 5x magnification lens for detailed views.

Features of Small Bench Optics

• Guide setting accuracy: ±0.05 mm (0.002”)
• High optical quality: resolution of 0.028 mm (0.001”)
• Viewing capacity: rounds up to 40 mm, ovals up to 40 mm full width
• Mylar templates: provided with passes for each product size

Main Benefits of Bench Optics

• Enhanced accuracy: facilitates high-speed rolling
• Reduced component stress: accurate alignment extends operational service life
• Quick setup: offline guide setting maximizes mill utilization
• Improved product quality: fewer defects and reduced material rejection

Portable Optics Systems

Large Portable Optics Systems for Intermediate and Pre-Finishing Mills

The Large Portable Optics System enables precise online roller guide bracket and restbar settings, achieving accuracy within ±0.1 mm of the theoretical pass centerline. Designed for larger Primetals Technologies roller guides, it enhances guide alignment and repeatability in intermediate and pre-finishing mills.

Features of Large Portable Optics

• Viewing capacity: rounds up to 48 mm, ovals up to 48 mm full width

Small Portable Optics Systems for Rod Finishing Mills

The Small Portable Optics System ensures precise online roller guide bracket settings, achieving accuracy within ±0.1 mm of the theoretical pass centerline. Compatible with USX finishing mill guide systems and other configurations, it enhances alignment accuracy and repeatability.

Features of Small Portable Optics

• Secure clamping: zero clearance ensures total repeatability
• Operator convenience: allows for quick and precise adjustment of guide mounting brackets
• Viewing capacity: rounds up to 34 mm, ovals up to 34 mm full width

Main Benefits of Portable Optics

• Detects crossed rolls: prevents the production of defective products
• Accurate guide centering: eliminates hooked front ends and minimizes cobbles
• Symmetry confirmation: ensures proper roll parting, reducing front-end defects
• Improved product quality: minimizes scratches and defects in the finished product