Anda di halaman 1dari 31

TECHNICAL DESCIPTION

WALDRICH SIEGEN
Heavy Duty CNC Roll Grinding Machine
ProfiGrind 2500
BOKARO STEEL PLANT
Attn.: Mr. B.B. Jha, AGM Design Bureau
Hot Strip Mill
Bokaro Steel City 827004
INDIA

Date:

Project
Responsibility:

Mr. Karl-Heinz Adamek


WALDRICH SIEGEN GmbH & Co. KG
Daimlerstrae 24 57299 Burbach Germany
0049 2736 493-331 Fax: 0049 2736 493-706
Email: Karl-Heinz.Adamek@Waldrich-Siegen.de

Representative: Mr. Kalyan Mukhopadhyay


Empire Machine Tools Empire House/Ground Floor
414, Senapati Bapat Marg. P.O. Box 16330
Lower Parel, Mumbai 400 013 INDIA
(0091) 22 - 4 93 37 40 Fax: (0091) 22-4 96 23 80
Email: empiremt@bom3.vsl.net.in

May 31, 2006

GENERAL INFORMATION

Table of Contents
1

TECHNICAL DESCRIPTION ...........................................................................................................3


1.1
Beds ......................................................................................................................................3
1.2
Headstock .............................................................................................................................3
1.3
Counterstay...........................................................................................................................4
1.4
Steady Rests (hydrodynamic)...............................................................................................5
1.5
Steady Rests (hydrostatic)....................................................................................................6
1.6
Grinding Carriage..................................................................................................................7
1.7
WALDRICH SIEGEN CP - Measuring System ...................................................................10

ProfiGrind Control PGC 10 Roll Grinder CNC Control System ............................................14


2.1
PGC 10 Controller Description............................................................................................14
2.2
Fully Automatic, Integrated Roll Grinder Control ................................................................17
2.3
Options for the PGC 10 Control ..........................................................................................21
2.4
Concave / Convex Continuous Path Grinding System .......................................................23

ACCESSORIES..............................................................................................................................27
3.1
B-axis ..................................................................................................................................27
3.2
Eddy Current System (EC) .................................................................................................29

ACCURACIES ................................................................................................................................31

May 31, 2006

TECHNICAL SPECIFICATION

TECHNICAL DESCRIPTION
To assist you in your selection of a roll grinder supplier, below is a listing of benefits
of WALDRICH SIEGEN engineering and design features:

1.1

Beds

Cross Section of Beds

1.2

Details of Design

Benefits

Two-piece bed casting design, onepiece workpiece bed with headstock


base, one-piece carriage bed; short
distance between adjustable wedge
shoes.

Machine maintains its accuracy over a


long period because rigid and separate
beds ensure that there is no influence on
the carriage bed when loading heavy
workpieces on the workpiece bed.

"Walk-on" telescopic way covers


(when the carriage is stationary).

The guideways are protected from harsh


outside environment; i.e. splashing water,
dirt particles, etc.

Headstock

Headstock

Details of Design

Benefits

Ribbed cast iron.

Exceptionally rigid and stiff.

Infinitely variable drive.

No gear steps and therefore an optimum


accommodation to the grinding technology.

May 31, 2006

TECHNICAL SPECIFICATION

Faceplate with floating driver.

Non-restrictive driving of rolls provides for


optimum roll surface finish.

Headstock drive motor.

Digital variable frequency AC-Motor (IP


54), highest balance class for vibrationfree motion.

Starting motor for higher workpiece


weights.

Starting inertia and friction are overcome


without overloading the main motor.

Headstock Starting Drive

1.3

Counterstay

Counterstay

May 31, 2006

TECHNICAL SPECIFICATION

1.4

Details of Design

Benefits

Manual adjustment in longitudinal direction and manual clamping on the


bed.

Easy adjustment for the compensation of


axial forces.

150 mm adjustment of hydraulic


counterstay live plate.

Less time for loading/unloading; less wear,


less adjustment on bed, reduced risk of
collision.

Steady Rests (hydrodynamic)

Hydrodynamic Steady Rest

Details of Design

Benefits

Two (2) jaw type.

Highest concentricity, roundness and


shape tolerances for grinding on roll necks.

May 31, 2006

TECHNICAL SPECIFICATION

1.5

Steady Rests (hydrostatic)

Hydrostatic Steady Rest (with chock support as Option)

Details of Design

Benefits

Bearing shell jaw type.

Highest concentricity, roundness and


shape tolerances for grinding on roll necks.

Hydrostatic

Higher roll weight possible


Lower initial breakaway torque

Principle Sketch of Hydrostatic

May 31, 2006

TECHNICAL SPECIFICATION

Principle Sketch of Hydrostatic and Hydrodynamic

1.6

Grinding Carriage

Z
B

Grinding Carriage (with B-axis as option)

Details of Design

Benefits

Longitudinal feeds :
6 - 9000 mm/min.

Full utilization of maximum feed rates for


auxiliary time-savings.

Surface cutting
45m/sec.

May 31, 2006

speed

up

to

High grinding quality and cutting performance as required in each application.

TECHNICAL SPECIFICATION

Grinding spindle secured eccentrically with hydrostatic bushing.

Wear-free operations at maximum load of


the grinding spindle, thus providing for
long-term precision even under heavy-duty
conditions.

Principle Sketch of Hydrostatic Bearing Housing for Grinding Carriage

Details of Design

Benefits

Hydrostatic lubrication (red marking)


of both longitudinal and cross
guideways and of the grinding spindle.

Wear-free operations at maximum load of


the grinding spindle, thus providing for
long-term precision even under heavy-duty
conditions.

NC-Axis Carriage with B-axis as Option (Principle Sketch)

Details of Design

Benefits

CNC-controlled roll barrel shape


grinding by a unique actuating
mechanism.

Quick and precise adjustment for grinding


of all profiles at unsurpassed accuracy.

Automatic grinding wheel retraction


in case of power failure.

Prevents damage to machine and workpiece.

May 31, 2006

TECHNICAL SPECIFICATION

Principle Sketch of WALDRICH SIEGEN Monobloc Design

Details of Design

Benefits

Single-piece upper carriage with hydrostatically lubricated guideways


and overgrips.

Exceptional rigidity with no carriage tilting.


Wear-free traversing and high performance grinding of rolls with a large diameter
range.

Automatic wheel approach.

Time-saving, operator independent operation provides a soft contact with the roll.

Infinitely variable and constantly


controlled wheel cutting speed and
maximum wheel speed limitation.

Ensures constant performance independent of grinding wheel wear while the


maximum permissible speed of grinding
wheel is controlled for operating safety.

Continuous infeed to compensate for


wheel wear.

Geometry of roll is maintained even during


heavy roughing operations.

The Z-axis drive consists of two


servo drives with rack and pinion,
each located at either end of the
lower carriage. The drives will be
electrical braced and run in master/slave mode. The measurements
will be carried out by a highresolution incremental transducer.

Zero backlash, due to the electrical bracing of the master/slave mode of the servo
drives.
Improved smoothness of running by deletion of the worm drive and shortening of
the drive track.
Higher feed rate in Z-direction (up to 12
meter/min) cycle time improvement.
The symmetrical arrangement of the
motors outwards on the lower carriage
improves the stiffness and avoids tilting
at the reversing points of the wheel.

May 31, 2006

TECHNICAL SPECIFICATION

Principle Sketch of Electronically Preloaded Drives (Z-Axis)

1.7

WALDRICH SIEGEN CP - Measuring System


Measuring equipment and measuring beam are mounted on top of the carriage for
measurement of roll shape, roll diameter, stock removal, concentricity and roundness in conjunction with the CNC control system.
The measuring beam is equipped with two (2) probes. This allows comparison between the programmed (rated) and the ground (actual) shape. The comparison
made between the rated and actual shape is the pre-condition to generate the "optimization grinding" features of the CNC control.
All measurements can be taken before or after the grinding process. Measurements
of diameter and stock removal can be done during grinding and are performed by
the outer probe.

Measuring System (CP - Type) (Principle Sketch)

May 31, 2006

10

TECHNICAL SPECIFICATION

Details of Design

Benefits

Highest accuracy.

Use of high resolution digital measuring


scales.

Automatic measurement.

All measuring beam movements (X1-axis)


and measurements are carried out automatically. The measuring arms are automatically moved until the measuring probe
tips come into contact with the roll.

Measurement during grinding process.

The outer measuring arm is operated during the grinding process to monitor stock
removal and roll diameter.

Reliability.

The measuring beam, arms and probe tips


are free of backlash, thus ensuring reliable
measuring results.

Versatility.

The following measurements can be


made:
Stock removal during grinding
Roll diameter during grinding
Diameter before and after grinding
Shape of the roll
Roundness of the roll
Eccentricity of the roll
Taper of the roll
Automatic alignment of the roll to be parallel with the carriage bed (optional)

Process integration.

The software of the roll measuring system


evaluates the measured data to optimize
the grinding process and prints out all results on request; thus, roll protocols are
established quickly, accurately and automatically.

May 31, 2006

11

TECHNICAL SPECIFICATION

Details of Design

Benefits

CP-Type Measuring System (Wheel-Side-Arrangement)

1.7.1

Measuring Device in Combination with the CNC


Most of the important features of the CNC control require interaction of a measuring
beam providing data feedback of grinding results to the CNC for comparison between rated and actual roll shape.
Features of our CNC in combination with the measuring beam are as follows:

Measurement of shape
Measurement of eccentricity
Measurement of out-of-round condition
Measurement of diameter
Measurement during the grinding process
Automatic grinding according to prorated stock removal
Automatic grinding according to prorated diameter of roll
Dual (mate) grinding of work roll pairs
Optimization grinding by comparison of rated and actual values
Automatic alignment of the roll to be parallel with the carriage bed (optional)

May 31, 2006

12

TECHNICAL SPECIFICATION

Alignment of the roll (optional) (Principle Sketch)

Average eccentricity determined (A-B)/2


No taper influence (A-B)/2
Direct in-process measuring (1:1 relationship)

May 31, 2006

13

TECHNICAL SPECIFICATION

ProfiGrind Control PGC 10 Roll Grinder CNC Control System

Overview of PGC 10

Main operator panel:

On carriage with full multiple color TFT service.

Auxiliary operator panel:


(push button / electronic hand wheel)
on carriage to allow manual interface

Main Operator Panel

2.1

PGC 10 Controller Description


The operator station consists of a 15" TFT flat screen monitor with a resolution of
1024 by 768 pixels and a choice of an industrial keyboard or a panel with individual
push buttons. Clever hardware makes it possible for the connection between the
computer and the operator station to consist of only two coaxial cables. For large
grinders two of these operator stations could be installed.

May 31, 2006

14

TECHNICAL SPECIFICATION

PGC 10: Hardware System Manger

The I/O (input/output) is made up out of a daisy chained string of I/O modules, which
allows decentralized placing of these modules anywhere on the machine, drastically
reducing wiring. Fiber optical communication allows for extremely fast updates,
while interference from conventional copper wiring is eliminated. The update rate of
this so-called Light Bus is over 1 MHz.

PGC 10: Configuration Screen for all Axis (Totally Open System)

The software platform chosen is Microsoft Windows XP, with a real time extension.
This stable operating system is widely used and lots of software tools are available.
The operator interface (or GUI, Graphical User Interface) is specifically designed for
roll grinder applications, while the look and feel of the previous generation of PGC
May 31, 2006

15

TECHNICAL SPECIFICATION

10 control systems is preserved as much as possible. Visual Basic was chosen as


the programming language. The logical part of the control software consists out of a
mixture of structured text and function blocks. This PLC style programming environment is IEC1131 compatible.
Full functionality, comparable with the previous control systems, is achieved.

PGC 10: Online Movement of all Axes for Service Purpose

Online diagnostic system is included.

PGC 10: Real Time Extension for Operation Speed of 1 ms

May 31, 2006

16

TECHNICAL SPECIFICATION

2.2

Fully Automatic, Integrated Roll Grinder Control


Details of Design

Benefits

Controller

Still the only real single process computer


controller, excluding internal interfaces

Type

PGC 10, based on industrial PC, field bus


system with fiber optic cabling

Most advanced for

Full integration of

Operation

Including - with compatible roll measuring system

May 31, 2006

Real time calculations


Extremely high-powered
Super fast for corrections with up-dated
data per new wheel stroke
Very flexible for 'real pick-out programming' in menu techniques (no working
through given schemes)
High resolution graphics for plotter type
quality pictures, of course scaled
All functions, possibilities and capabilities of
chapters:
Concave / convex continuous path control
grinding system - CNC
Roll measuring and inspection system
By use of the one above mentioned process
computer
Fully automatic with 'auto screen'
Fully flexible programming also matrix
type
Programming with operator's guidance
(dialog) for all mentioned geometrical data
and texturing parameters as well as procedures for functions (sequences), menu
techniques in clear (no computer) language
Programming in 'choose and pick
method', no inflexible following of preset
procedures and rules is required
Help functions/screens are available
TFT monitor for operator's comfort including true graphics of high resolution
On-line respectively in-process measuring
operations with permanently updated, real
time data feed back for possible in-process
corrections and / or logical decisions automatic (adaptive control).

17

TECHNICAL SPECIFICATION

Details of Design

Benefits

Fully automatic grinding fault correction

Direct recording of the measured actual


curve in control computer; there, the ideal
input curve is compared against the measured curve, and these both curves are
automatically plotted (screen and printer).
The grinding correction is superimposed
based on the above results.

In-Process corrections

Thanks to the computer's fast rate of reaction, when measuring during grinding, an
actual correction curve will be calculated
and actuated during each of the return
grinding strokes.

Full graphics - plotter type

A multi-colored high power screen is used


for permanently monitoring the curves:
ideal - actual tolerance.

Grinding to tolerance

Upper and lower tolerance curve are preselectable; the shape grinding process is
automatically stopped once the actual
curve lies within the tolerance range and for
example the removal target is reached. The
next cycle then immediately continues.
Roll shape creation by the concave/convex,
continuous path CNC grinding control.

Operator Screen "Auto Cycle"

May 31, 2006

18

TECHNICAL SPECIFICATION

Details of Design

Benefits

Main operator's panel

With full multiple color TFT service


On carriage
Optionally on floor and on carriage

Auxiliary panel

On carriage to allow manual interference

High level diagnostics

Extensive 200 fault diagnostics down to


board level with code number and clear
language written explanation on TFT

Software programming

On main panel after passing code words to


reach different operating and / or service
levels

Program data back-up

Standard for 100 rolls (additional capacity


as option)

Extended by

RSMS interface via database on the roll


grinder control and CD ROM or network

Full TFT monitor for

May 31, 2006

Programming in menu techniques


Roll data monitoring on high resolution
multiple color TFT scaled presentation,
zoom window enlargement of curve sections
Manual data input via keyboard
Program recall by name
Extensive override screen for all
variable parameters
Program interruption, restart, repetition etc.
Special operator's help function (operator
calls control for help to know what to do
next, control answers in clear language)

19

TECHNICAL SPECIFICATION

Details of Design

Benefits

Help Function

Whenever the operator or maintenance man looses track of what to do next, he


pushes the Help function key. The control then gives clear language instructions
how to proceed. The instruction appears in the actual window.
Storage of

100 different, complete roll grinding programs to be recalled by program name


only, storage in control of each grinder,
matrix programming also with different
curve grinding programs

Functions

Longitudinal roll alignment


Roll coupling
Inspection cycle with report especially of
initial roll diameter
Parallel roll alignment incl. software alignment correction by use of superimposed
compensation taper to compensate for a
possible mechanical rest error
Plausibility control whether the chosen
program matches the loaded roll by position check-up of counterstay or steadies
Eddy current surface inspection with logic
about extent of surface damages (option)
Extension of the eddy current detection
with ultrasonic measuring
Wheel dressing cycle
Adjustment for constant cutting speed

May 31, 2006

20

TECHNICAL SPECIFICATION

Details of Design

Benefits

Grinding sequences with

Contour or shape as required incl. end relief cut grinding

By use of

All possible grinding parameters such as


roll, wheel, carriage speed, wheel infeed
etc.
Roughing: especially with continuous
infeed for stock/damage removal, or 'device for grinding high barrel ends'
Semi finish grinding: for dimensional corrections, matching of rolls
Finish grinding: for grinding (shape) fault
corrections 'on-line' use of measuring system
Sparking out: especially with continuous
finest infeed for polishing rolls obtaining a
critical surface finish

Measurements and inspections

Incorporated into the program whenever


and wherever wanted

Final measurement and inspection


report

As described under 'roll inspection' on tag,


on TFT, in central computer or on printer

Set back of all components

Into reference/home positions

The CNC control

Is an own development using readily available out-of-shelf components

Note:
It is obvious that all roll measuring functions require choosing the roll measuring and
inspection system if not already included in the basic scope of supply.
In case of fully automatic roll grinders, sometimes automatic roll loading / unloading
systems are required. We have developed different systems including roll storage
racks.

2.3

Options for the PGC 10 Control


Details of Design

Benefits

Control for taper grinding

Closed loop control of the X- and Z-axis of


the grinding carriage (cross and longitudinal) to allow grinding of all required tapers
having freely selectable lengths

May 31, 2006

21

TECHNICAL SPECIFICATION

2.3.1

Details of Design

Benefits

Control for spiral vent-a-nip groove


cutting - Optional extension for progressive spiral grooves available.

Closed loop control of the axes of headstock and carriage to allow thread cutting of
all required pitches

Control for eccentric compensation


grinding - Optional extension for
automatic data input available.

Grinding of the outer surface of a shell concentrically to its inner bore, by use of correction values.

Text on TFT screen bilingual


German / English and Chinese. The PC control system allows for different languages. In case you would like to have the different screens in Chinese language,
we will send over to the Buyer the respective text that has to be translated. Afterwards, we will implement your translation into the PC controller. In principle, this will
be done for all operator screens, not for service screens.
The basic language will be English or German as required by you.

2.3.2

Extended Diagnostics
The standard fault system provides excellent detection for over 200 possible faults
on the machine. An optional extended diagnostics system provides additional features that complement the standard fault detection system.
The extended diagnostics enhance the fault detection system by providing aids to
maintenance personnel when a fault is detected and extending the fault detection to
time-dependent failures which are not detectable by traditional fault detection systems.
In operation, this provides the extended features of displaying the complete logic
associated with the detected fault. This aid to maintenance provides on-line information in relay ladder form (graphically displayed on the operator's TFT). This means
that, once failures are detected, the time to resolve the problem is reduced.
Additional aids include tracing of selected inputs, outputs and flags and also the ability to scroll through the relay ladder logic. A clear text description and color indication of status of inputs, outputs and flags is also provided.

2.3.3

Scope View
Via a scope view system it is possible to view I/Os and flags as well as variables. In
the logbook the user actions, overrides, messages, faults PLC-messages and sequential function carts (SFC) messages are logged.

2.3.4

Possible To Interface With (Option)

Central roll shop computer (WALDRICH SIEGEN RMS),


Programming for roll grinding
Programming of software
Operating services

May 31, 2006

22

TECHNICAL SPECIFICATION

2.4

Monitoring services
Storage capabilities
SPC-capabilities
Roll history built-up
Roll tracking, scheduling
Full up- and downloading
Program back-up service
Your host (main frame) computer preferably through central roll shop computer

Concave / Convex Continuous Path Grinding System


The process computer controlled crowning system has been especially developed
by WALDRICH SIEGEN to fulfill the special demands of the industry. It is fully incorporated into the single process computer control of the roll grinder.

2.4.1

Highest shape flexibility


Easiest, graphically aided roll shape creation (GAC system) in menu techniques
and clear language dialog
Roll shape storage and automatic integration of the selected shape into the
grinding program
High level, on-line adaptive control capabilities for roll shape correction grinding,
roll alignment error compensation, machine bed misalignment correction
Highest availability by: high level diagnostics, use of readily available "off-theshelf" components

Roll Barrel Shape Flexibility


Details of Design

Benefits

Electronically range
Sinus curve

10 mm on radius
26 - 180 degrees angle section

Different Roll Shapes

May 31, 2006

23

TECHNICAL SPECIFICATION

Details of Design

Benefits

Shape variations using different sine


angle sections

Sine Curves with Different Chamfers

Barrel end relief to be ground in one


cycle with the roll barrel
One side or both sides, mirror
type or different
Multiple end relief sections are
possible

Compound: different sine curves


Tapers
Radiuses
Flat middle sections
Exponential/parabolic

Compound curves

From the above mathematical curves

CVC / CVCplus shapes

Input by coefficients formula up to seventh


degree

Required input data

Profile value:
a1: ..........................E6
a2: ..........................E9
ax:...........................Ex
a7: ..........................E24
Barrel start: ............mm
Barrel end: .............mm
Mirror:.....................yes/no
One-button mirror function for tope and
bottom rolls

Arc grinding
Empirical curves

May 31, 2006

Continuous path control by data point


input (station-to-station) - CVC etc.
Station-to-station raster: free choice of
interval raster
Circular interpolation

24

TECHNICAL SPECIFICATION

2.4.2

Correction Capabilities To Be Superimposed Onto Above Curves


Details of Design

Benefits

Guide path corrections input values


Grinding fault correction input values
Software correction of parallel roll
alignment

Station-to-station input 0.002 - 0.99 mm;


based on radius
Station-to-station input 0.0001 - 0.99
mm; based on radius
Compensation taper to compensate for
possible mechanical alignment error

Crowning range

The whole offered crowning range including


correction capabilities is worked through
the highly accurate eccentric U-axis.

Further tools for possible improvements:

Wheel width compensation - shifting continuously calculated, based on roll


shape profiling
Z-axis speed profiling for faster grinding
Amperage profiling continuously calculated based on empirical customer's data
for constant wheel pressure independent
of wheel width actually on roll
Z-axis reference point shifting
Multiplication factor for crown height correction
Working curve storage, feed forward correction based on empirical customer's
data

Grinding Wheel Width Compensation (Principle Sketch)

May 31, 2006

25

TECHNICAL SPECIFICATION

Details of Design

Benefits

Adaptive control.
In case of adequate roll inspection
system and automatic grinding package

Fully automatic grinding fault correction by


direct recording of the actual, measured
curve in the control computer; after a programmed measuring cycle, there, the ideal
curve is compared with the measured
curve, and the correction curve is automatically superimposed

Shape Error Correction (Principle Sketch)

May 31, 2006

26

TECHNICAL SPECIFICATION

ACCESSORIES

3.1

B-axis
For swiveling of the grinding wheel face for fast and precise CVC grinding.
Developed, designed and patented by WALDRICH SIEGEN, the B-Axis offers the
possibility to use a roll grinding machine at highest accuracy, exceptional surface
quality, reduced wheel wear and to achieve shortest grinding times. One reason for
its development was the high edge-wear when grinding roll curves with a large variety of diameters. (CVC-curves for example)

Standard (without B-axis)

with WALDRICH SIEGEN B-axis

Technical Advantages of the B-axis used on heavy Roll Grinders (Principle Sketch)

May 31, 2006

27

TECHNICAL SPECIFICATION

By using the B-axis WALDRICH SIEGEN roll grinding machines are capable to position the grinding wheel always vertically to the corresponding curve tangent, which
offers the following advantages:
Increase grinding machine performance in a cold rolling mill by up to 30 %
Reduced grinding times by using maximum machine performance
Reduced wear of the grinding wheel (and possibility to use harder wheels) and
increase of the grinding wheel contact area
Increase of the roll shape accuracy and simultaneous improvement of the surface quality.
Technical Data
Swiveling angle of grinding wheel to accommodate generated line
Swiveling angle...................................................................

deg.

0,225

Feedrate .............................................................................

deg./s

0,0833

Torque (servomotor) ...........................................................

Nm

Speed range .......................................................................

rpm

1 - 4000

Resolution...........................................................................

arcs

0,858 x10-5

May 31, 2006

28

TECHNICAL SPECIFICATION

3.2

Eddy Current System (EC)

3.2.1

Roll Inspection System


For all roll applications there is a request for an equipment to localize defects of rolls
for higher safety within the rolling mill, higher quality and optimized re-grinding purposes.
As a roll manufacturer you will use the equipment for ensuring and computerized recording of the quality of your rolls.
This continuous process in your roll shop for identifying and quantifying roll defects
will enable a grinder operator to remove the precise amount of material from a roll to
eliminate all detrimental defects before the roll is sent back to the mill.
The system can be installed on an existing grinder as a stand-alone unit or fully integrated into our grinder control. It is designed to minimize mill downtimes and lower
the operating costs for the mill.
With the real time identification of the defects on the surface of the roll, your grinder
operator is in the position to determine exactly the amount of material removal that
is required to render the roll acceptable for supply to mill or roll user.
Eddy current system
The eddy current roll inspection system can be used as follows:
Eddy current roll testing to check for surface defects, magnetism and bruises

Eddy Current (Principle Sketch)

3.2.2

Roll surface inspection


Eddy current roll surface inspection
The eddy current inspection system (EC tester) is used for checking the roll surface,
detecting cracks and chill cracks up to a depth of 3 mm, hardness increases and
hardness variations as well as magnetic fields. In order to be able to detect these
defects, they have to start at the roll surface.

May 31, 2006

29

TECHNICAL SPECIFICATION

The effective width of the eddy current inspection head is 40 mm (optional 13 mm).
The eddy current roll inspection can be carried out during the grinding process. With
several passes during the grinding process the complete surface of the roll is
checked.

Eddy Current Sensor

May 31, 2006

30

NOTES

ACCURACIES
Manufacturing and installation of our grinders are performed according to WALDRICH SIEGEN geometric acceptance regulations TKA 121 00 002 CP per German
DIN and ISO Standards.

Machine System Accuracy


(Accuracies below are based on radius)
Roundness .........................................................................

mm

0,001

Eccentricity .........................................................................

mm

0,002

Straightness of generated line............................................ mm/m

0,001

Taper (conical form) ........................................................... mm/m

0,0025

Shape accuracy (0,1mm height of crown) ......................... mm/m

0,002

May 31, 2006

31