Straightening plants meeting high demands

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1 Straightening plants meeting high demands Benefits at a glance Optimized straightening results High productivity and reliability Higher product quality and better residual stress behavior Wide product range Long service life and minimized wear through long-life components Higher flexibility and availability due to automated quick roller change

2 Roller Straightening Machines A new standard for straightening of Long Products. SMS group is one of the leading global system suppliers along the entire metallurgical value chain of our customers. The plants and machines manufactured by the SMS group fulfill the production requirements of a wide and demanding product spectrum. Modern section mills have to produce a wide variety of shapes and sizes as these are the demands of today s market of structural sections and rails. Of critical importance is maintaining a high utilization factor in the mills by minimizing unscheduled and scheduled stoppages. Of the latter, it is paramount importance reducing size changing times. The latest technology for roller straightening machines is the CRS Compact Roller Straightener. The CRS designs are employed in medium and heavy section mills and represent the following technology: Higher product quality and better residual stress behavior Symmetrical application of the straightening force with the rollers supported on both sides Automatic straightening roller changing within 20 minutes Fixed straightening roller pitch for a large product range Automated straightening roller changing with less personnel The straightening rollers of sandwich design are supported by bearings on both sides. All nine straightening rollers are individually driven, while the hydraulic cylinders allow the rollers to be adjusted under load. The CRS roller straightening machine is characterized by the following features: Overload protection Backlash-free mounting of straightening rollers Maximum concentricity of straightening rollers Automated setting of all adjustments mechanisms and drives according to the straightening data set-up Position transducers for reproducible recording of all setting values The design features of CRS roller straightening machines are as follows: Operator pulpit for CRS roller straightening machine Symmetrical application of straightening force Hydraulic axial position of each straightening shaft Compensation of spring by hydraulic adjustment mechanisms Automated straightening roller changing with 20 minutes by changing platform on floor (double side/ single side) or by changings manipulator due to bay requirement Adjustable last straightening roll (roll no. 9) for optimized straightening results 2

3 Roller Straightening Machines Type CRS H Workshop assembly of CRS roller straightening machine at SMS group workshop in Mönchengladbach 3

4 Types and sizes of CRS roller straightening machines The SMS group offers different sizes which are optimized for any demand. The CRS will be used to straighten sections i.e. H-Beams, I-Beams, Channels, Rails, Equal or Unequal angles, Sheet Piles, U and Z, Universal flats and special sections. Below is an overview of the actually types/sizes. Type Vertical straightening force max. section modulus Product range up to CRS ,850 kn 450 cm 3 Web height: max 550 mm Flange width: max. 300 mm Web height: max 600 mm CRS ,850 kn 570 cm 3 (CRS 1600 S) (2,800 kn) (900 cm 3 ) Flange width: max. 300 mm (Web/Flange: max. 750/300 mm) CRS ,800 kn 900 cm 3 Web height: max 750 mm Rails Rails 509 cm 3 Flange width: max. 300 By max. tensile strength of 1,100 N/cm 2 CRS ,000 kn 1,930 cm 3 Web height: max. 1,000 mm Flange width: max 400 mm CRS ,000 kn 2,800 cm 3 Web height: max. 1,250 mm Flange width: max 500 mm * Based on yield point of 420 N/mm 2 The CRS roller straightening machines are equipped with one main drive for every straightening shaft. Every shaft is axially adjustable by one hydraulic cylinder to optimize the alignment of the straightening discs. The motor power will be customized according to the straightening program and the required productivity. A straightening speed up 8 m/sec is possible. The machine is equipped with a protection against scale for a long service life and reduced maintenance requirements. The scale may be disposed via conveyor belt or suction device. CRS roller straightening machine special feature adjustable bottom roll no. 9 A special feature of the CRS roller straightening machine is the adjustable bottom roll no. 9. This roll is equipped with an eccentric system for an adjustment range of ± 25 mm. This feature allows the influence of the up or down sweep without the re-adjustment of all other straightening rolls. 4

5 Automatic quick change concepts The roll change of the CRS roller straightening machine will be executed automatically within 20 min. The changing concept for CRS roller straightening machines can be customized according to customer or building requirements. The changing platform for the straightening discs can be arranged on both entry and exit side (double side changing platform) or on either side (single side changing platform) of the straightening machine. If the installation space for a changing platform is restricted, a changing manipulator can be installed above the straightening machine. One example for a changing procedure with a double side changing platform is shown in the following picture. 1. Shifting of operator side housing together with the used straightening rollers 2. Side shift of 1st changing car to take-over the used straightening rollers 3. Side shift of 2nd changing car with new straightening rollers into the straightener 4. Shifting of operator side housing back with new straightening rollers in operating position Automatic changing of straightening rollers by changing platform (double side) Adjustable roll no. 9 Entry guide (with horizontal and vertical rolls and entry guide) Front view CRS roller straightening machines with entry and exit guide rollers 5

6 Straightening plant for rails The SMS group offers our customers rail straightening plants consisting of horizontal and vertical straighteners to process the highest quality rails, eliminating waviness and achieving straightness in full accordance with relevant international rail standards,. The straightening machines are applicable to fulfill the latest high speed rail standards for the latest generation of high speed trains. High-speed railway lines in Germany, Spain, Italy, France, Korea, Japan and China are laid with rails straightened almost exclusively on rail straighteners from the SMS group. Additionally to the special features of the CRS roller straightening machine is the rail straightening plant by SMS group which exhibits the following features. High housing rigidity Blacklash-free mounting of rollers and sleeves on the straightening shaft with a special design of the mounting sleeves Single drive system for each straightening shaft Individual adjustable last roll of horizontal and vertical straightener The straightening plant consists of one horizontal CRS roller straightening machine and vertical cantilever straightener. The machines are characterized by a very rigid, robust design with one individual main drive for each straightening shaft. An offline setup-model, in combination with a special tension control between the straightening rollers, enables optimum residual stress levels to be achieved in the product to ensure maximum service life of the rails on track. Rails straight as an arrow ensure safe running of high-speed trains worldwide Vertical Straightener in operation 6

7 Off-line setup model Horizontal CRS Straightener Type CRS HS & Vertical Straightener Type VRM 1300/1200/ Machine The setup model calculates off-line the adjustment position of the straightening rollers in vertical directions. After inputting the technological boundary conditions, physical parameters and the geometry of the product, the required adjustment positions of the straightening rollers will be determined in relation to the straightness and the remaining residual stresses of the profile type and size. The results of the SMS group off-line setup model are: Offline calculation for all sections and rails in order to get preset values for roller adjustment Optimization of roller adjustment with respect to straightness and minimized residual stresses Output of geometric and mechanical values Process data analysis and re-calculation of settings Off-line roller straightener setup model visualization screenshots 7

8 Conventional Roller Straightening Machines Conventional roller straightening machines find application in Medium and Light Section Mills. These cantilever type straightening machines, with a fixed or adjustable roller pitch, are designed for a wide product range. Horizontal Straightener Type HRM1400/1250/1100 8M The conventional SMS group roller straightening machines are characterized by the following design features: Compact and rigid machine housing Axial position of all straightening shafts Simple elimination of scale due to smooth housing fronts Traction of rollers by bayonet ring and high- pressure hydraulic clamping nut Data management to preset machine settings Single drive for each straightening shafts Machine is available with height adjustment and or shiftable as option 8

9 Horizontal Straightener Type HRM MRAIL Horizontal Straightener Type HRM M 9

10 References HISTORY 2015 SMS group GmbH Paul WURTH S.A. SMS group 2011 elexis AG SMS group SMS group has a long and versatile experience for planning and execution such roller straightening machines for all different kind of applications. The experience is based on numerous machines delivered by the predecessor companies Schloemann, Siemag, Demag, Meer, Krupp, Möller & Neumann and Sack. With our continuous further development and the numerous roller straightening machines supplied, we have the major influence on the modern design and technology of straightening machines Paul WURTH S.A. SMS Siemag AG SMS Demag AG Schloemann-Siemag Aktiengesellschaft Concast AG SMS Demag AG SMS Schloemann- Siemag AG SMS Meer GmbH Siemag Siegener Maschinenbau AG Mannesmann Demag Hüttentechnik Meer elexis AG elexis Elektroholding GmbH Mannesmann Demag AG More than 450 roller straightening machines have been delivered by the SMS group worldwide to all leading rolling mills in Europe, North America, South America, Africa, Australia and Asia S.A. Anciens Etablissements Paul Wurth Schloemann AG Schloemann GmbH Siegener Maschinenbau AG Demag AG Maschinenfabrik MEER Aktiengesellschaft For more details please refer to our separate reference list for roller straightening machines Paul Wurth KGaA Eduard Schloemann OHG Carl Eberhard Weiss Schmiedebetrieb Deutsche Maschinenfabrik AG Gebr. Meer Maschinenfabrik u. Eisengießerei 1870 Eugène Müller Kesselfabrek Dahlbrucher Eisengießerei Gebrüder Klein Mechanische Werkstätten Harkort STRONG MARKET POSITION. CUSTOMER FOCUS. DECENTRALIZED RESPONSIBILITIES. CORPORATE CULTURE 10

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12 SMS group GmbH Business Unit Long Products Product Unit Heavy Section & Billet Mills Ohlerkirchweg Mönchengladbach Deutschland Phone: Fax: W2-318E Published on Circulation 500 Printed in Germany KD The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.