A slitter that cuts both stainless steel and titanium, saving energy


Stainless Steel & Titanium Slitting Line FLOREANI & P. New [#3347]
   Slitting lines SLL   Stainless Steel & Titanium Slitting Line  FLOREANI & P. New [#3347]

New Stainless Steel & Titanium Slitting Line
1650mm x2.5mm | F-Class

    A Quick Tool Change Slitting Line
    (Tooling Transfer Unit Type)
This line is installed at THYSSENKRUPP AST, Sabbiona (Terni), Italy.

It allows processing both stainless steel and titanium coils and has:
- energy saving AC drive motors
- quick slitter tooling changer ( > #3257, at the bottom of the page )
- a straightener incorporated
- a Siemens WINCC flexible monitoring system installed

Other features of the line are:
25 t decoiler with 420-620mm mandrel expansion range
auto. edge control with self-alignment (+/- 150mm)
paper recoiler
mobile strip tensioning unit
coil cars

Process materials thickness: .3mm to 2.5mm
Minimum strip width: 30mm

Max. 25 slits are possible at .3mm thickness
Max. 8 slits at 2.5mm thickness

Our “World-Class” Slitting Lines for
- max. 2000mm-wide coils
- material thicknesses up to 8mm* (* M.S.)
- coil weights up to 40 t
(with max. speed 400m / min)
typically include:
- auto. coil edge guide
- entry & exit crop shears
- a quick tool change system
and, often come with also:
- quickly interchangeable mandrel drums
- coil storage ramps and/or turnstiles
- a coil banding system...

From: "DEFORMAZIONE" Magazine

A slitter that cuts both stainless steel and titanium, saving energy

At the ThyssenKrupp AST stainless steel service centre in Sabbiona in the province of Terni, a slitting line has been installed allowing the undifferentiated processing of both stainless steel and titanium coils. A series of innovative solutions were applied, beginning from the use of AC motors to achieve noteworthy energy savings.

Stainless steel and other innovative materials such as titanium are fast becoming the materials of choice in the industrial sector. The reasons are many, not least of all the aesthetic appeal of both materials, an essential trait in the high-tech furniture and building sectors, as well as their intrinsic properties such as hardness, toughness and resistance against corrosion, making these materials perfect for use in food, chemical and aeronautical sectors.
Both materials need to be processed using technologically advanced machinery in order to be transformed into commercial steel products such as strips and sheet metal. Slitting lines and surface finishing machinery have been the subject of strong demand in recent years following the growth of so-called Service Centres, which in many cases have replaced steel mills, in particular for coil processing services. One of these very centres has revamped their production facilities, affording us the opportunity to talk about an innovative new slitter for stainless steel and titanium coil processing. The line was installed along with another three surface finishing machines (polished and brushed) at the ThyssenKrupp AST stainless steel service centre in Sabbiona in the province of Terni.

A unique slitter for two materials that are different, yet similar to cut.
We're talking about a slitting line for longitudinal cutting, which, being directly connected to the Thyssen steel mill in Terni, has been integrated with extremely robust machinery able to process coils up to 25 t each. Our attention is immediately drawn to the line’s ability to process both stainless steel and titanium, provided the coils are anywhere between 500 and 1,650 mm wide and between 0.3 and 2.5 mm thick. A unique feature, which isn't the result of any particular studies or the use of special techniques, given that these two metals behave very similarly during the unwinding, cutting and rewinding of strips. "With this slitter, Thyssen cuts 60% stainless steel and the remaining 40% titanium". "This isn't the result of any particular construction technique, but rather simply owing to the fact that both materials are very similar to cut. This is made possible by the fact that the same blade assembly is used when switching from one material to another, provided the width of the strips needing to be cut doesn't change. So as long as the strip width is the same, all you need to do is set the thickness and width of the material, along with the cutting speed, in order to set and configure the line. Of course, during processing the operator can always make any corrections if needed".

Processing control and remote assistance
Before we explore the line's configuration to trace out a brief profile, it's worth taking a look at some of the features making this system a particularly innovative construction. For example, the use of alternate current motors as compared to continuous current ones, with clear energy savings, or the Siemens WINCC Flexible monitoring system, which automatically controls the entire line and which is able to generate alarm signals in the case of malfunction.
"An enormous focus was placed on the electronics," explains the line manufacturer, "both those for operator control and those responsible for driving the entire system. A process monitoring and control system has been installed on the line, which through a video system allows the operator to execute all line preparation operations and configure parameter settings, but also to monitor all the parameters and alarms during operation. Thanks to the potential of the monitoring system, the operator is able to see the line in motion on the synoptics screen and can therefore assess each processing step in real time, at any time. The monitoring system is an extremely useful tool also for maintenance purposes; thanks to our remote assistance service, we can in fact see 90% of the line by remote, thereby acting promptly and solving the problem from our operations centre without the need for a technician to be physically on-site".

Alternate current motors guarantee energy savings
Energy savings was another important topic. Unlike previous lines built by the manufacturer, this one is equipped with alternate current motors used to drive all the main functions of the line and thereby minimising energy consumption. In this case, the brake motors act as generators that produce energy in a common busbar, which is then used for secondary motor power. The line therefore absorbs less energy, given that the accumulated energy is redistributed within the line, rather than being dispersed as heat. "The amount of energy consumed by the line is an important aspect", reiterated the manufacturer. "It is not difficult to understand that for a steel mill in the process of revamping their existing machinery park, the availability of four new lines with this type of solution translates into important energy savings. Among other things, in some cases this also means that the transformers in the facility don't need to be replaced, yet another source of savings".

The line's coil loading and unwinding units
Moving on in order, it's worth mentioning that this slitter is able to process - at a speed of 150 m/min - coils up to 25 t each, with a maximum external diameter of 2,000 mm (both in input and output) and an internal diameter in input from 508 to 610 mm (with mandrel segments). The minimum width of finished strips is 30 mm and the number of possible cuts with stainless steel and a tensile strength TS of 800 N/mm2, for example, is 25 with thickness 0.3 mm, 15 with thickness 1 mm, 10 with thickness 2 mm and 8 with a 2.5 mm thick coil. The maximum scrap width is equal to 5 mm, with maximum thickness 1 mm, and width in line with the material's tolerance.
Looking at the line's configuration, it is important to note that the coil loading unit is composed of a coil car and dual-position coil skid for a minimum coil diameter of 900 mm, which are used for coil storage. The loading coil car is mobile and is mounted onto 7,200 mm long tracks using hydraulic motors. It has a vertical stroke of 950 mm by hydraulic cylinder and is equipped with two idle rubber rollers lined with Adiprene used to centre the coil on the decoiler mandrel, complete with a strapping groove. The line also features automatic coil loading onto the decoiler mandrel.
The unwinding unit is composed of a decoiler with front support and a 1,700 mm mandrel with saw tooth, completely machined and ready for the assembly of Ertalon mandrel segments with an expansion range from 520 to 620 mm; the mandrel expansion range without segments on the other hand varies between 420 and 520 mm. Coil alignment is automatically and hydraulically controlled by way of a proportional photocell +150/-150 mm (300 mm in total); similarly, mandrel expansion is also automatically and hydraulically controlled. Other features of the decoiler include: hydraulically controlled pressure arm with 600 mm long idle rubber roller and central strapping groove; safety and stationary brake; possibility for top and bottom unwinding; paper recoiler with pneumatic expansion.

Configuration of coil head introduction unit
Very importantly, given the type of material being processed, the coil head introduction unit - positioned downstream of the decoiler - is composed of a dual-roller feeding module, a tilting and telescopic hydraulic positioning table with plastic lined sliding surfaces, an idle straightener with four Adiprene lined rubber rollers and hydraulic crop shear. The feeding module is composed of two Adiprene lined rollers: the top mobile idle roller is hydraulically powered, while the lower one is motorised. The useful passage is 1,655 mm, while for the roller table it is 1,680 mm.
The straightener has a straightening capacity of 2.5 x 1,650 mm (Rmax800 N/mm2) and features two fixed lower idle rollers and two upper idle rollers that can be vertically adjusted. The only role of the straightener is to eliminate the curvature of the coils, and not to correct any defects in the material. Penetration by the upper rollers is achieved using AC motors and jacks, and is controlled by a Siemens control desk. The vertical position of the rollers is shown by indicators on a progressive scale. The crop shear too has a cutting capacity of 2.5 x 1,650 mm (Rmax 800 N/mm2) and a useful blade length of 1,680 mm. The blade descends by way of a mechanical torsion bar and the cut coil head falls away when the table opens. The shear uses four-edge blades and is equipped with upper and lower blade protection rollers and a rapid blade clearance regulator with a visual indicator.

"Thanks to the remote assistance service we are able to see 90% of the line by remote, thereby acting promptly and solving the problem by remote, without the need for a technician to be physically on-site".

The dual-arm carousel allows quick blade changes
And now we come to the heart of the slitter, or rather the longitudinal slitting unit, whereby an idle plasticising machine with three supports (two upper and one lower) allows the top part of the material to be covered with a protective film, if necessary.
The guide unit with tempered rollers and independent motorised regulation for the centring of coils in the cutting blades facilitates the introduction of the material in the circular shear, equipped with 1,655 mm wide axles. The main features of the circular shear are worth noting: the motorised opening of the eccentric axles with blade position and penetration readings; the front mobile shoulder with hydraulic command and complete front axle opening with longitudinal and transversal movements; blade stopping by way of greased lock nuts mounted onto the front mobile shoulder; motorised blade holder axles with double reduction gear reducer and telescopic universal joints; electronic indicator of blade penetration. A dual-arm carousel positioned at the front of the slitter allows rapid blade changes, unloading and loading them from the blade holder axles. The carousel arms are positioned at 180°, feature a 1,250 mm stroke and sliding is facilitated by precision guideways with ball bearing blocks, with hydraulic gear motors and position blocking. The automatic blade loading and unloading system is mounted on the circular shear with a hydraulically controlled pusher. The blade assembly change time is approximately 8 minutes, excluding the time to prepare the pack itself, which can be coordinated separately thanks to the external carousel.

Rotary tension stand or felt press?
Downstream of the circular shear, apart from the side scrap winder, the role of the table with looping pit overrun installed on the scrap conveyor unit is also particularly important. By way of the felt press used to clamp the ends, it guides the strips towards the recoiler. The main table with looping pit overrun works as a feeding saddle by way of Adiprene lined rubber rollers located at the start of the table.
Basically, as the scrap is recovered, the strips enter the looping pit for the various strip lengths. They enter the pit, exit the pit and are then guided across the overrun table, which inserts them directly into the motorised braking carriage containing the mobile tensioning unit, consisting in AC motorised bridle rollers and a felt press depending on the fragility of the material being processed. "In the case of materials whose external appearance isn't all that important," specifies the line manufacturer, "a felt press is used with adjustable pneumatic pressure, which in reality is nothing more than an adjustable passive braking system, which determines the tension of the strips being wound. If the material must be in perfect condition, rubber bridle rollers are used, which when connected to an AC motor tension the strips and create resistance against their rewinding. There is one last idle deflector roller at the tensioning unit exit, with a 400 mm diameter and lined in Adiprene, which moves vertically by way of hydraulically controlled jacks. The entire tensioning unit is installed on a mobile carriage that slides on precise linear guideways, which picks up the slit strips near the shear, clamps them and takes them to the recoiler".

The recoiler and coil discharge carousel
During the winding phase, the strips are inserted into the recoiler mandrel where they are automatically clamped during the expansion phase. There is also a sensor to position the mandrel clamp when the coils are introduced. With the mandrel completely closed, it is possible to assemble the Ertalon sleeve with a slit through which to introduce material into the clamp, thereby modifying the expansion range of the mandrel itself. The recoiler is equipped with a hydraulic pressure arm with an idle spacer-holder roller in steel, and a photocell for the automatic and progressive rise of the arm during winding. Similarly, in the case of the decoiler, the maximum traction is 6,000 kg and the nominal inner coil diameter is 508 mm.
A discharge coil car and 4-arm carousel downstream of the recoiler complete the line configuration. The carousel has a 25 t capacity on each arm and is positioned centrally with respect to the recoiler mandrel; it is hydraulically powered with automatic positioning every 90° and features a position blocking system. The discharge coil car, equipped with a "button" pressure arm, allows the unloading of slit coils from the reels, depositing them on the carousel for the next strapping phase, so as to limit the line's idle time as much as possible.

We offer quality Slitting Lines both new and used / re-manufactured for Aluminium, Coated, Cold Rolled, Copper, Galvanized, Hot Rolled, Prepaint, Silicon, Stainless, Tinplate,

Your enquiries welcome for also individual Line Parts like: Decoilers, Recoilers, Slitters, Strip Tension Stands, Turnstiles, Upenders ...
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