The analysis and countermeasures for the roll tower shape issue in the steel plate coiler at Hou Junshan Dagang Steel Co., Ltd. and Taigang Stainless Steel Co., Ltd. are essential to ensuring product quality and operational efficiency. The hot milk plant, which mainly produces stainless steel, has an annual production capacity of 530,000 tons, with about 300,000 tons of coil plates produced each year. The end coiler is responsible for the final stage of coiling, where the steel plate thickness is 1.6 mm, width ranges from 651 to 550 mm, and the coiling degree is between 3.58 and 8.58. However, due to aging equipment, serious tower shapes often occur during the coiling process, leading to quality issues and affecting sales.
Several factors contribute to this problem. First, the reel drum is a cantilevered structure, and over time, the axis becomes misaligned due to gravity, resulting in an inner tower shape. Additionally, the gap between the leading roller and the horizontal upper roller is inconsistent, making it difficult to maintain even pressure during coiling. The axis between the reel and auxiliary roller also lacks parallelism, causing uneven contact and further contributing to the formation of a tower shape.
From a process perspective, the linear speed of the drum rotation must be higher than the milking speed to prevent the steel plate from drifting. When tension is applied, any imbalance can lead to either an inner or outer tower shape. Furthermore, when the tail of the steel plate leaves the milk stick, the loss of tension can cause the plate to swing, forming a tower shape. Lastly, the reel's rising position during coiling may not contract properly, leading to inconsistencies in diameter and ultimately a tower-shaped coil.
To address these issues, several technical measures have been implemented. These include comprehensive improvements to the reel and its deceleration system, reinforcing the foundation, and aligning the reel axis with the rolling mill axis. Ensuring that the motor maintains a higher current during coiling helps sustain constant tension and prevents drift. Adjustments to the feeder, such as lowering the roller level, also help reduce the likelihood of tower shapes.
Automation technologies, including sensor-to-machine control systems, have been integrated into the electromechanical setup to enhance productivity and reduce the need for manual labor. Sensors monitoring pressure, temperature, roller height, flow, vibration, and shock provide accurate data for real-time adjustments, improving system stability and performance.
Regarding explosion protection, the use of vacuum contactors and circuit breakers ensures reliable short-circuit protection. Designing labyrinth structures or increasing the gap on explosion-proof joints enhances safety. The shell’s thickness should exceed 4.4 mm, and pressure relief devices are being developed to minimize internal pressure during arc short circuits.
Finally, by addressing both equipment and process-related causes, the company has significantly improved the quality of its steel coils, restored product sales, and reduced economic losses. Through continuous improvements and proactive maintenance, the long-term reliability and efficiency of the coiling process have been ensured.
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