- Force Measurement
- EdgerKraft
Rolling Force Measurement in Edger Mills
Find out how direct rolling force measurement in Edger Mills with the IMS EdgerKraft improves process stability, width accuracy and product quality.
Edger mills play a central role in the rolling process in the controlled reduction of the width of slabs and semi-finished products. Modern systems generate pressing forces of up to 2,200 tonnes and enable a width reduction of up to 350 mm.
The forces occurring during this process must be precisely measured and monitored to ensure consistently high product quality, safe equipment operation and optimum process control.
Rolling force is one of the most important process variables in the Edger Press. Reliable rolling force measurement enables continuous monitoring of the actual forming forces, optimization of control loops and protection of the equipment against overloads. At the same time, it provides valuable data for quality management, process optimization and modern Industry 4.0 applications.
For this demanding measurement task, high-precision rolling force load cells such as the IMS EdgerKraft Circular are increasingly being used. The load cell, specially developed for edger mills in steel rolling mills, measures the rolling force directly in the force path and provides a precise measurement signal for process control, equipment protection and automatic width control (AWC). Compared with conventional methods that derive the rolling force from hydraulic pressure, direct force measurement enables significantly higher accuracy and contributes decisively to improved width accuracy, higher productivity and consistent product quality.
up to 2,200 tonnes
width reduction of up to 350 mm
Challenges in Rolling Force Measurement
Measuring rolling force in edger mills places high demands on the sensor technology
used.
High Pressing Forces
With forces of up to 2,200 tonnes, edger mills operate in a range that requires
particularly robust and precise measurement systems.
Dynamic Loads
Short load changes and rapid control processes require high signal dynamics and
fast signal processing.
Extreme Environmental Conditions
In rolling mills, numerous factors affect the sensor technology:
- Vibrations
- Temperature fluctuations
- Water and cooling media
- Scale and contamination
- Continuous mechanical loads
The measurement systems used must provide reliable and reproducible results even under these conditions.
Direct Rolling Force Measurement with the IMS EdgerKraft Circular
For applications in Edger Presses in steel rolling mills, direct force measurement has established itself as a particularly precise method. One example is the IMS EdgerKraft Circular, a high-precision rolling force load cell specially developed for the requirements of edger mills.
In contrast to conventional solutions that only estimate the rolling force via hydraulic pressure, the EdgerKraft Circular measures the actual force directly in the force path. This reduces measurement uncertainties and achieves significantly higher accuracy in process control.
Technological Features
The IMS EdgerKraft Circular is based on modern strain gauge technology and was
designed for continuous operation under demanding rolling mill conditions.
Its key features include:
- Direct rolling force measurement for maximum measurement accuracy
- High-precision strain gauge technology
- Robust mechanical design
- High long-term stability and reproducibility
- Reliable operation under extreme environmental conditions
- Easy integration into existing measurement and automation systems
Use Under Difficult Environmental Conditions
Edger Presses place high demands on measurement technology. The EdgerKraft
Circular is specially designed for use under the following conditions:
- High dynamic loads
- Strong vibrations
- Temperature fluctuations and temperature extremes
- Water and cooling media
- Scale and contamination
- Continuous operation in an industrial environment
This enables precise and reproducible measurement values to be provided even
under harsh production conditions.
Advantages over Pressure-Based Measurement Methods
The biggest difference compared with conventional methods lies in the direct
measurement of the actual force acting on the system.
This provides operators with:
- Higher measurement accuracy
- Faster control response
- Improved width accuracy
- Reduced scrap
- Higher productivity
- Greater transparency of the forming process
IMS EdgerKraft Controller (MMV): The Intelligent Evaluation Unit for Precise Rolling Force Data
High-precision rolling force measurement requires not only powerful sensor technology, but also reliable and flexible signal processing. The IMS EdgerKraft Controller (MMV, Modular Measuring Amplifier) forms the central interface between the EdgerKraft load cells and the higher-level automation and control systems in the rolling mill.
The controller can be connected to any IMS RollKraft or EdgerKraft load cell based on a strain gauge bridge and processes the measurement signals with high speed and accuracy. The signals recorded by the force sensors are first processed via a fixed preamplifier and then digitized. Complete signal adaptation is software-based and therefore fully digital. This considerably simplifies parameterization and enables a high degree of flexibility when adapting to different equipment and process requirements.
Flexible and Modular System Design
The standard EdgerKraft Controller has two input channels for IMS EdgerKraft load cells. Thanks to its modular design, the system can be expanded by up to two additional input channels if required, without affecting the processing speed.
This makes the measuring amplifier suitable both for new systems and for the modernization of existing Edger Presses and rolling mill systems.
Seamless Integration into Automation
For connection to existing control and supervisory systems, the MMV provides
various communication options:
- ±20 mA analogue outputs
- ±10 V analogue outputs
- Optional fieldbus connection
- Support for EtherCAT
- Support for Profinet
- Transmission of measurement data and status information
- Full remote control of the controller via fieldbus
Through fieldbus integration, the controller can not only provide measurement values, but also receive control commands and configuration data. This enables close integration into modern automation and AWC systems.
Easy Retrofitting and Modernization
Four digital inputs and outputs enable the system to be integrated into systems
without fieldbus infrastructure. This makes the EdgerKraft Controller ideally suited as
a replacement for older electronic units.
A particular advantage: Existing IMS load cells can continue to be used. Extensive
mechanical modifications or replacement of the sensor technology are often not
required.
Fast Commissioning and Convenient Operation
The EdgerKraft Controller is housed in a robust stainless steel enclosure with
dimensions of 350 × 300 × 80 mm and features an integrated operating unit with:
- Four-line LCD display
- 20 characters per line
- Four function keys
Parameterization and commissioning can be carried out directly on the device. In
most projects, however, the systems are delivered already preconfigured,
significantly reducing the effort required for on-site installation.
Advanced Diagnostic and Configuration Options
The EdgerKraft Controller (MMV) Configurator software for Windows systems is optionally available. It enables:
- Convenient configuration
- Data backup
- Parameter management
- Offline analysis
- Documentation of system settings
This enables maintenance and service work to be carried out efficiently and system
configurations to be traced at any time.
The Ideal Addition to the IMS EdgerKraft Circular
In combination with the IMS EdgerKraft Circular, the EdgerKraft Controller forms a powerful complete system for direct rolling force measurement in Edger Presses. While the load cell measures the actual rolling forces directly in the force path, the controller ensures precise signal processing and reliable provision of the measurement values for AWC systems, process optimization and equipment protection.
The result is more precise control processes, improved width accuracy, higher equipment availability and a sustainable increase in product quality in the rolling mill.
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Uwe Fliegenschmidt
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