[Rolling Line Download Requirements
Amancio Mccrae
Before starting with the project, CS Wind Malaysia performed several capacity calculations to evaluate new production methods and setups to achieve the desired capacity in a production area dedicated to the rolling of cans for wind tower composition. CS Wind Malaysia then chose Faccin Group as its supplier because of its powerful automatic rolling system which solved the challenges posed by the company, with the addition of reduced production times.
Thanks to the high level of professionalism and commitment of the entire CS Wind Malaysia team, we were able to design and deliver a tailored product for this significant project. Regular meetings and progress reports ensured that all interfaces, specifications, and requirements were guaranteed and fulfilled. This exclusive collaboration has been rich in content and above all fully satisfying as we have solved all the challenges with the implementation of dedicated solutions to ensure maximum productivity of CS Wind Malaysia, says Diego Morbini, Technical Sales Manager and part of Faccin WT division.
With a pressure of 6,000 bar, food is gently preserved in high-pressure containers. To illustrate: This corresponds to a pressure at a sea depth of 60 km. Such special processes require high-performance technology and extraordinary machine components.
This is where the profiled wire from voestalpine Wire Technology comes into play. These special flat wires for the reinforcement of high-pressure containers for the pressure treatment of foodstuffs are produced in the new rolling line for profiles (KPWA for short) at the voestalpine Wire Technology location in Bruck an der Mur.
But what happens with this type of food preservation? The packaged food is surrounded by water and exposed to extreme isostatic pressure from all sides in a pressure chamber. This preserves the consistency and ingredients of the food, while complex harmful organisms such as bacteria & viruses die.
Reinforcement wires are required for these high-pressure chambers, as explained by the head of process technology, Franz Ptzelsberger, i.e. the high-pressure containers are surrounded by a special profiled wire that can counteract the great forces that are built up inside the container for food preservation.
The advantage of high-pressure treatment is that the pressure is distributed exactly evenly throughout the product and you don't have to wait until the temperature has reached the core, as it is the case with heating. According to the Organization of the German Agricultural and Food Industry, these advantages should be reflected in an annual increase in products treated in this way of more than 15% over the next few years.
But the investment in the new KPWA is not just about gaining a foothold in food processing, but rather positioning itself as a full-solution supplier in the profiled wire sector. The new facility is extremely flexible and ensures access to new markets.
Sales Manager Fiton Sadikaj also emphasizes this: "We are facing even more complex challenges than before. For this, the KPWA 7 expands the dimensional range of our profile wires." The range of products now starts at 2 mm instead of 6 mm wire cross-section and opens up additional fields of application with an extraordinary height-width ratio.
"In addition," emphasizes application engineer Hubert Kberl, we are further increasing the surface quality and thus being optimally equipped for the high demands of our customers. Together with the customer, we fine-tune the underlying steel alloy and optimize the processing, for example in terms of fatigue strength or corrosion resistance."
The quality requirements of customers are already implemented and fulfilled at the Wire Technology location in Bruck and proven with high-quality products e.g. with reinforcement wires for flexible oil and gas field pipes - also in acid gas-proof execution - complicated contoured profile wire solutions for hose couplings and demanding applications for circlips and spiral springs in the automotive industry.
With its expanded range of wire cross-sections and an annual capacity expansion of 1,200 tonnes, the new rolling line for profiles enables the voestalpine Wire Technology Group's production site in Bruck / Mur to become a full-solutions supplier in the profile wire sector for key customers.
voestalpine Wire Technology is a leader in the production of wire rod, cold heading wire, flat and shaped wire, prestressing steel wire and strands. Our products are used in the automotive supply industry, energy and construction technology, as well as in mechanical engineering and railroad infrastructure.voestalpine Wire Technology is a total supplier of technical and economical wire solutions for innovative customers.
The VFD used in the production line have been out of production for many years, and the spare parts supply cycle is long and there also has a risk of supply interruption, which brings major hidden dangers to production security. A high-reliability and high-performance domestic transmission product is needed to achieve seamless replacement to ensure the stable operation of the equipment.
INVT has formulated a transformation plan based on the actual needs of customers, using INVT GD800 series engineering transmission VFD to replace the original rolling line 380V sixth section transmission cabinets and 1-5 group cold roller table transmission cabinets, with a total of 17 cabinets. Communicating with the host computer TDC system through Profibus-DP, the GD800 inverter adopts seamless replacement software and is fully compatible with the DP communication protocol of the original inverter without modifying the TDC system.
INVT completed the protective dismantling of the original cabinet, installation of new cabinets, electrical construction, and equipment debugging within 8 days. The equipment operation met the production process requirements and was put into production on time.
In addition to this project, INVT has cooperated closely with a steel company on multiple products and projects, including lime kiln/rotary kiln, comprehensive utilization of waste heat recovery at public facilities, dry quenching coke silo for in-plant transportation, etc. Won the Excellent Supplier Award from the Steel Company.
INVT has been deeply involved in the steel industry for 21 years. Relying on its accumulated technical advantages, high-performance products and complete after-sales services, INVT has achieved stable operation of equipment, serving the sintering, pelletizing, ironmaking, steelmaking, steel rolling and acid production of the steel industry. Washing and other process sections have been continuously recognized by high-end major customers.
Drive solutions for general industrial processes such as conveying and lifting can usually be achieved with standard gear units and gearmotors. However, there are also applications that require these standard gear units to be modified so they fit perfectly.
Frequently, the on-site circumstances are so specific that special gear units are required to be produced in a single-unit batch. We are able to build these special constructions in our own facilities thanks to our industrial expertise and years of experience. We work in close cooperation with our customers and in association with our global production plants.
For example, we manufacture for the steel industry, including shiftable hoist drives for ladle cranes and customer-specific gear units for leveling machines, reels and pinions for rolling mills. With our customized gear units for new systems and "drop-in" gear units for updating systems, we can help many other industry sectors and applications achieve smooth operations. All this with a high degree of value creation for ourselves, for example in the manufacture of gearing components and shafts or case hardening, etc. As a result, we are always able to ensure the highest level of quality and reliability for our customers.
Leveling machines are an indispensable element of the belt feed when manufacturing sheet steel. A particularly robust and compact special gear unit is required to ensure the material being fed in can be aligned perfectly in the rolling line. This gear unit must drive multiple shafts evenly, thus enabling the repeated bending and reliable alignment of the sheet metal.
Particularly robust and complex special gear units are required for rolling mills in the steel industry. Depending on the number of rollers, these gear units are constructed with one or more output shafts. Alongside the continuous duty, these customer-specific solutions have to cope with especially high thermal and mechanical loads. You are always on the safe side with our perfectly customized special gear units.
A four-stage differential gear unit is at work in the primary hoist of a 180-metric ton ladle crane. This powerful unit weighs a total of 15.8 metric tons and is driven by two motors, each with a power rating of 191 kilowatts. With the motor power installed, this drive achieves an operating torque of 225 000 Nm and a nominal gear unit torque of 500 000 Nm.
A special feature of this gear unit is the integrated planetary superposition stage, which safeguards the functionality of the hoist even if one of the motors fails. This ensures that the lifting process can still be completed at full torque at half the hoisting speed.
Handling freight containers, for example, also involves critical applications that require a special gear unit. In the crane hoists here, we use gear units that are shiftable while idle so as to bridge motor failures. This makes it possible to double the gear ratio and carry out an "emergency lift".
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