The analysis and countermeasures for the roll tower shape issue in the steel plate coiler at Hou Junshan Dagang Steel Co., Ltd. and Shanxi Dayuan Taigang Stainless Steel Co., Ltd.'s hot milk plant is a critical concern. This facility primarily produces stainless steel with an annual production capacity of 530,000 tons, including approximately 300,000 tons of coil plates. The end coiler is the final step in the coil plate manufacturing process, where the steel plate thickness is 1.6 mm, width ranges from 651 to 550 mm, and the winding degree varies between 3.58 to 8.58. Due to aging equipment and OTHER factors, serious tower-shaped coils are formed during the winding process, which do not meet production or quality standards. This issue affects product sales, leads to quality disputes, and causes financial losses for the company.
**Analysis of the Causes of the Winding Tower Shape**
1.1 The reel drum is designed as a cantilevered structure, and due to gravity, the axis of the reel tends to become misaligned over time. This misalignment leads to an inner tower shape forming during the coiling process.
1.2 The roller system consists of a lower roller and a horizontal upper roller, but the axes between them are not perfectly aligned. This results in uneven gaps between the rollers, which can cause the steel plate to form a tower shape during winding.
1.3 The axis between the reel and the auxiliary roller is also not parallel, leading to inconsistent gaps. As a result, the steel plate cannot be evenly guided into the reel, causing a distorted shape.
**Process Factors Analysis**
2.1 During the winding process, the linear speed of the drum must be greater than the feeding speed. If this condition is not met, the steel plate may drift, resulting in either an inner or outer tower shape.
2.2 When the tail of the steel plate leaves the milking stick, if the tension is lost, the plate may swing left and right before being fed into the reel, contributing to the formation of a tower shape.
2.3 The reel should contract during the steel pushing process, but due to long-term wear, its expansion and contraction capabilities are reduced. This can lead to an uneven coil head, creating a tower shape.
**Technical Measures to Eliminate the Tower Shape**
To address these issues, several technical measures have been implemented:
2.1 A comprehensive improvement of the reel and its deceleration system has been carried out. This includes reinforcing the foundation and aligning the reel's axis with the rolling mill’s axis to minimize movement during operation.
2.2 The tension control system has been optimized to maintain a consistent level of tension by ensuring that the motor current during winding is higher than when idle. This helps prevent the steel plate from drifting.
2.3 Adjustments have been made to the feeder system, lowering the roller level to ensure proper alignment and reduce the risk of tower formation.
2.4 Automation technologies such as sensor-based machine control have been integrated into the electromechanical systems. These technologies enhance productivity, reduce labor requirements, and improve operational accuracy.
2.5 Sensors monitoring pressure, temperature, roller height, flow, vibration, and shock have been developed to provide stable and accurate data. This supports the development of a large-capacity mobile airborne computer system for real-time monitoring of the coal machine’s working parameters.
**Measures to Prevent Explosion from Arc Short Circuits**
With increased supply voltage and improved electrical equipment capacity, the risk of arc short circuits due to insufficient voltage or overvoltage has risen. To mitigate this, vacuum contactors and circuit breakers are used to ensure reliable short-circuit protection. Additionally, labyrinth structures and explosion-proof joint surfaces are designed to enhance safety. The explosion-proof shell’s protection level must reach IP154, with wall thickness exceeding 4.4 mm to reduce internal pressure during faults.
**Final Adjustments**
Adjusting the position of the lower roller on page 55 ensures it is not below the thickness of the coiled steel plate. The gap between the feed roller and the reel must be adjusted to remain slightly smaller than the steel plate thickness, maintaining tension even after the tail is flicked.
**Conclusion**
Through detailed analysis of both equipment and process-related causes, and by implementing appropriate technical solutions, the quality of the steel coils has significantly improved. This has led to better product sales and helped the company recover from previous economic losses.
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