For copper cold rolling and foil rolling, several types of mill are selected according to the rolling process, thickness and materials to be produced. Our typical mill type is the UCM-Mill, which is suitable for rolling to thin gauge. The alternative X-Mill technology is another of our typical mill type for thin copper and copper alloy foil rolling. 4Hi, 6Hi, 12Hi CR mill and 20Hi ZR cluster mill are also applied by us for cold rolling of copper and copper alloys.
The UCM-Mill for copper and copper alloys features small work rolls (WR) combined with shape control functions consisted of WR bending, intermediate roll (IMR) bending, IMR shift using all straight uncambered rolls and a spot cooling system. Rolling of hard and thin material with excellent shape control is realized in the UCM-Mill. Furthermore, equipped with a cobble guard and air wiping system at the mill exit side and good wiping ability can be achieved during high speed rolling.
Fig.1- UCM-Mill | Fig.2- Copper products | Fig-3 UCM-Mill Operating side
The X-Mill with intelligent shape control using Sheet flat is designed for ultra-thin strip/foil rolling. The rolls are arranged in an X configuration in which a pair of parallel back-up rolls support each side of the small diameter work rolls at a tangent below the WR top to prevent horizontal deflection. This enables stable and reliable thin-gauge rolling to be performed.
Fig.4- X-Mill (Tension Reel) | Fig.5- X-Mill (Operating side)
- Compact and simple mill arrangement
- Optimized mill size and layout
- Stable rolling
- Automatic mill set-up
- High speed rolling
- Minimal downtime
- Quality product
- Optimum integrated control
- Automatic flatness control
- Automatic gauge control
- Optimum integrated control system
- Optimum roll size and motor power
- Quick hose connection for roll changes
Continuous improvements of the quality of rolled aluminum products together with increasing demands regarding mill uptime and productivity are strongly supported by new developments and enhanced functionality of Primetals Technologies electric and automation applications for rolling mills.
Today's demands for flexible and economic production of aluminum plate, aluminum strip or foil can only be met by electrical and automation solutions, that are based on profound knowledge and a deep understanding of the aluminum rolling technology. This kind of know how in combination with our expertise in mathematics, physics, control algorithms, mechanical, hydraulics and electrical engineering qualify Primetals Technologies to design and develop technological process models, high-performance control systems, reliable and mill proven drive systems, as well as all other electrical equipment necessary for the operation of rolling mills. In short, Primetals Technologies is able to supply complete mills or rolling mill equipment from one source. All our solutions are well approved and have been optimized in many applications with well-established customers all over the world.
Modern automation concept for improved product quality on Aluminum Foil Mills
Technological controls and process models are the core of our modern automation concept with the goal of maximizing utilization of the mechanical, electrical, hydraulic and other controlled equipment.
The control concepts have evolved with the increasing performance of the equipment and increasing demands in terms of tolerances of the final product– from simple analog PI controllers to highly complex and interlinked control systems. These controls and process models are nowadays integrated and the added value is well seen in the resultant strip quality.
These added values are:
- World class thickness and flatness tolerances to meet growing demands worldwide,
- Less off-gauge material,
- Maximum throughput and availability
Scalable Technological Control Systems for Aluminum Foil Mills
These highly standardized EA packages have modular design and defined interfaces.
- Short delivery times thanks to the use of standardized components with high availability
- Fast start-up due to a field-proven solution with references around the world
- High product quality due to integrated suite of quality control functions
- Compact design with highly integrated components and allow installation even in confined areas
- Trouble free implementation due to modular design for new mill plants as well as for upgrades, extensions and revamps also of 3rd party systems
- Additional upgrades with add-on packages allow state-of the art improvements of functionality, strip quality and higher mill productivity even as a later retrofit
- Attractive CAPEX due to standardized solutions
Integrated Digital Drive Systems
Integrated fully digital systems with full capability of technological and diagnostic performance are designed for drive control using high speed multi-microprocessors.
Flexible applications range from single drives with pinion gears to integrated drive systems for twin-drive and tandem-drive. DC converters, AC cyclo-converter drives and AC multilevel drives, cover the wide range of power and voltage ratings required. Comprehensive software development tools and libraries are supplied as part of the system. Diagnostic capabilities with local display of messages, operator control and monitoring are included in the applications.
Technological controls and process models
Primetals Technologies provides a highly standardized TCS (Technological Control System) as a core for the automation of Aluminum Cold and Foil Mills.
The TCS is embedded into a project specific application which is tailor – made to suit the individual automation task. The range of available tools includes the full range of options for Aluminum Foil Mills including model based flatness control and an advanced mill set-up system for fast and smooth acceleration and maximum throughput. It further includes all relevant gauge and flatness control algorithms for all thickness ranges and alloys. Primetals Technologies offers a fully integrated automation concept which is completed by a user friendly HMI and diagnostic system for intuitive and effective operator support. This can be configured from almost manual operation for simple applications to the highest automation level featuring e.g. auto threading and tail out, automatic roll - change.
General benefits are:
- Steep start-up curves as the "physical knowledge" from many mills is available right from the start
- Integrated automation with high flexibility
- High accuracy through making use of the experience with many thousands of strip mills
- Extension of behavior to new alloys and to new dimensions
Experience on Aluminum Foil Mills
Over the recent decades Primetals Technologies has successfully automated literally dozens of Aluminum Foil Mills all over the world, cooperating with world-class Aluminum producers. The range of Primetals Technologies references covers the full range of Foil mill applications from Universal-, Roughing- and Intermediate-Mills to Finishing Mills rolling ultra-thin gauge as well as Bright finishing mills.
Type of Plant:
Reversing Cold Mill featuring UCM-Mill
Primetals Technologies UCM-Mill for excellent gauge and shape control, and high quality of product.