Synopsis of New 20 High Cold Reversing Z Mill Drives and Automation Solution Project

Situation: A copper and copper alloy producer in China constructed a new Z Mill with a production throughput capacity of 30,000 metric tons/year. The Z Mill produces light-gauge copper foil used in the production of products such as printed circuit boards. To produce copper of such light gauge, the following specifications apply: Mill Speed: 0 - 800 MPM; Tension Range: 90 – 27,000 lb; Strip Gauge: 0.05 – 3.0 mm; Strip Width: 310 – 650 mm; Coil Diameter: 610 – 1850 mm. Issues: Strict tension accuracy requirements, including ± 3% at constant speed and ± 5% during acceleration or deceleration. Requirement: A world-class drives and automation solution. Technology: Siemens 6SE70 Simovert Masterdrives Power Platform, Siemens FM458, Siemens S7, Siemens Simolink, Siemens WinCC, Profibus, ET200.

Brock Solutions' Role: Developing a Functional Specification; designing the hardware architecture and supplying related hardware; building a complete multi-panel drive package to contain all of the project’s required variable frequency drives; building all required operator desks and pushbutton stations; programming PLCs/HMIs; integrating the controls with external systems (e.g., automatic flatness control, automatic gauge control, x-ray gauges, Level 2, etc.); configuring diagnostic software; performing simulation and testing exercises; conducting a Factory Acceptance Test (FAT); supervising installation activities.

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