Professional Documents
Culture Documents
Principle
Special anti-friction bearings and the fact that the machine features one movable and one stationary roll permit the two rolls to adjust themselves obliquely to each other during material feeding. This means that varying gap widths are established at the two roll ends (being the maximum and minimum distance between the roll shell surfaces) and different hydraulic pressures in the two cylinders of the movable roll. Consequently, two sensors each have to be installed for measuring gap width and pressure.
4 .
Roller Press
Roller dist. = 10 mm fix + Bearing dist. = 0 mm Gap = 10 mm
measured by Limit switch Gap sensor
RP - Frame
Retraction cylinder
Press cylinder
Fixed Bearing
Distance block
Movable Bearing
2 Sensors for monitoring shut-off gate position Grease lubrication system consisting of 1 Pump for of the roller bearings, 1 heating unit for the grease barrel including temperature controller, 1 heating unit for the grease pipes including temperature controller and resistance thermometer PT100, 1 signalling contact for monitoring the minimum grease flow rate behind the grease pump, 2 signalling contacts (one each at the two progressive distributors) of the grease lubrication unit for the roller bearings. 2 differential pressure monitoring of the gear oil filter 2 speed sensors for under speed monitoring of the rolls 1 Lubrication oil system with circulation pump, 1 feed pump, 1 Heater for oil in the reservoir ( oil tank ), 1 Stirrer within the oil reservoir ( oil tank ), 3 Solenoid valves, 4 Resistance thermometers PT100 for monitoring oil temperatures, 10 Oil flow sensors for monitoring the oil flow and 3 heating units for the oil pipes including temperature controller and resistance thermometer PT100 1 Servo drive for feed regulating gate 1 ROLCOX control panel with control system, power supply and terminals for all external cable connections local junction boxes for the collection of all signals at the Roller Press 1 local operating panel for the operation of the hydraulic valves in local mode
9
The control unit is designed as closed system for the Roller Press based on the hardware platform S7300. The interface to the client control system is performed via discrete I/O`s and a Profibus DP - standard interface.
10
Local operation box for the operation of the Roller Press hydraulic system in LOCAL mode during troubleshooting and maintenance activities, consisting of: 4 push buttons for manual control of the hydraulic pressures at the movable roll 1 push button with signal lamp for alarm acknowledgement. The signal lamp is energized at specific, unacknowledged alarms. 1 mushroom push button for emergency stop 4 digital indicators for indication the hydraulic pressures and the bearing distances at the left and the right side of the roller press.
11
Control unit
The control unit is designed to control the following drives of the Roller Press: 2 Roller drives 2 Gear oil pumps 1 Grease barrel pump 1 Hydraulic pump 2 Proportional valves for pressure control of the hydraulic system 1 Solenoid valve for emergency shut-down 2 Solenoid valves for pressure decrease 2 Solenoid valves ( bypass valves for pressure release ) 1 Solenoid valve for moving the two rolls apart by the help of the retraction cylinder 1 Servo drive for the feed regulating gate 1 magnetic valve for the pre-bin shut-off gate
Left
Fixed Roller
Retraction cylinder
Right
V 1/2
Retract. cylinder
V 3/4
5312HD1.V 3/4
Movable Roller
V 05
5312HD1.V 05
Press cylinder
V 06 V 09 V 08 V 10 V 07 V 05 V 06 V 09
5312HD1.V 06
5312HD1.V 07
5312HD1.V 09
V 1/2
V 3/4
V 10
5312HD1.V 10
V 07
V 08
5312HD1 V 08
Emergency valve
M01
5312HD1.M01
Hydraulic pump
12
Pump 5312.HD1
13
HYDRAULIC SYSTEM
Hydraulic set consists of : 1 hydraulic pump, 2 proportional valves for pressure control, a number of solenoid valves for pressure decrease, bypass valves, valves for the retraction cylinder and valve for pressure release in case of an emergency shut-down, 1 resistance thermometer PT100 for monitoring of the hydraulic oil temperature in the reservoir accumulator, 1 temperature limiting switch for the hydraulic oil reservoir
14
5312HD1. V 1/2
5312HD1.V 3/4
5312HD1.V 06
5312HD1.L01
Tank level
5312HD1.V07
5312HD1.H01
Tank heater
Temperature measurement T > 70 C RP STOP with ALARM 5312HD1.T01 Tank temperature > 40C 5312HD1.T02 T > 50 C Alarm T < 20 C Heating OFF T < 15 C Heating ON
15
Hydraulic layout:
Fixed value: 50 C for Hydraulic oil temperature (warning) Fixed value: 70 C for Hydraulic oil temperature (fault, group Roller Press STOP) If the temperature exceeds the above fixed value, the roller press is stopped with an alarm.
16
5312LQ5. M01
Feed Pump
5312LQ55 M01
17
Terminal box Oil re/filling pipe
L > Max 3 L > Max 2 (Early morning) L < Min Pump LQ4.M01 OFF
18
OIL LUBRICATION SYSTEM
Roller press bearing lubrication
Bypass-Valve 5312LQ5.V01
5312LQ5.T03
5312LQ5.T02
5312LQ5.T01
19
Oil Lubrication governors for Longitudinal bearing Adjusted for 3,75 l/min Measuring range 0 10 l/min
Oil Lubrication governor for radial bearing Adjusted for 1,5 l/min Measuring range 0 5 l/min
1 Flow NOK max 3 ours, 2 Flows NOK max 15 min, then stop Roller Press
20
Oil Lubrication governor for radial bearings Adjusted for 1,5 l/min Measuring range 0 5 l/min
21
22
Grease lubrication for roller bearings
The grease lubrication consists of a grease tank with grease pump and two progressive distributors each mounted on the left- and right-hand side of the roller press. Grease conveying of the pump is monitored by a pressure switch. In case of a failure an alarm is created. In addition, each progressive distributor has been provided with a switch which is operated at each stroke of the piston of the progressive distributor at the cycle of grease distribution.
23
In order to guarantee a sufficient grease supply to the roller bearings, the signals from the pressure switch and the progressive distributors are analyzed.
24
25
The bearing distance is measured at the left- and right-hand side of the movable roll. Since the distance between the roll surfaces inside the gap cannot be measured directly, the distance between the housings of fixed and movable bearing is used as a measure. The sensors are inductive position sensors with integrated transducers. The transducer is of a four-wire type. The measuring range is 0 -100mm. The output signal is 4 ... 20 mA. In case of wire breakage, a fault signal is generated and the roller press group will be stopped.
26
Pressure measuring
The pressure is measured with one pressure sensor each on the left- and right-hand side of the movable roll. The corresponding transducer is of a two-wire type. The measuring range is 0 ... 400 bar, the output signal 4 ... 20 mA. Sensor and transducer are accommodated in one housing. In case of wire breakage a fault signal is generated and the roller press group will be stopped.
Pressure transmitter
27
Temperature measuring
The roller bearing temperatures and the gear box bearing temperatures are measured at every test point with one resistance thermometer PT100 each. These thermometers have been connected in three-wire technique to the temperature transducer. The transducer is of a two-wire type. The measuring range is 20 +100 degC, the output signal is 4 ... 20 mA. In case of wire breakage a fault signal is generated and the roller press group will be stopped immediately.
Temperature PT100 sensor of one bearing measurement
28
29
33
open close
Fixed Roller
Movable Roller
32
33
34
RP Trouble, trip, Group off, automatic
35
SCADA
RP Trouble, trip, Fast stop automatic
36
37
Left Fixed Roller Gap = 45 mm
Start RP group
At every start the emergency valve V08 is energized to close the hydraulic circuit.
Right
To release the oil of the main cylinders the bypass valves (V09 and V10) and the pressure decrease valves are energized (opened). This will occur with standing rollers. The movable roller will be moved by the retraction cylinders to L2 + 10 mm = 45 mm
11 V 06
V 06 09 10 V 05
08 V 09
V 10 07
L min L2 + 10 mm
V 1/2 V 07
V 3/4
After reaching of L2 + 10 mm, the main drives will be started one by one.
Pump 5312.HD1
38
39
The sum of L3= (L2 + L2incr.) must never exceed the maximum travel range of the hydraulic pistons.
40
Left Fixed Roller Gap = 35 45 mm Right
Start RP group
Retraction cylinders are drawn back by springs. After this the movable roller will be pushed back to L2 by the main cylinders from 45 mm to 35 mm. This happens with running rollers.
L2
Gap = 35 mm
In case if during moving back the movable roller an oil pressure is measured of more than 40 bar ( normal < 40 bar ), the start will be interrupted by an alarm signal. Fault has to be acknowledged at the roller press after checking. Possible causes: Material between the rollers. Disturbance in the hydraulic circuit. Roller can not move free. After bearing distance is on both sides L2 the roller press group will be released and feeding of the pre bin can be started. Pump stops and valves will be closed.
V 06 09 V 10 05
07 V 09
V 10 07 06 V 11
V 1/2 V 07 08
V 3/4
After L2 will be reached - the shut off Gate will be opened to release material flow to the rollers.
Pump 5312.HD1
41
Left Fixed Roller Right
Movable Roller
Press cylinder
After opening of the shut off gate there will get material between the rollers.
V 10
V 09
V 08
V 05
V 06
V 1/2 V 07
V 3/4
The proportional valves will increase pressure to the main cylinders up until the set point. Hydraulic pump start.
Pump 5312.HD1
42
Left Fixed Roller Right
Pressure control
By the intake behaviour of the running rollers combined with the pressure of the column ( gap ) of material on the rollers the material flow will tend to press the rollers apart. When the hydraulic reaches the value set point-tolerance the proportional valves will be closed and the pump will stop.
V 06
Movable Roller
Press cylinder
V 09
V 08
V 10
V 05
V 1/2 V 07
V 3/4
Pump 5312.HD1
At this value the material counter pressure and the cylinder pressure will be on balance.
43
Left Fixed Roller Right
Pressure control
Pressure variations with in tolerance will be compensated by the N2 accumulators.
Accumulator Gas ( N2 ) Pressure = 90 bar
100 90 bar
100 bar
Movable Roller
Press cylinder Start up < 90 bar Set point 125 bar
135 bar 125 bar 115 bar
V 09
V 08
V 10
V 05
V 06
V 1/2 V 07
V 3/4
Pump 3212HD1.M01
44
Fixed Roller Left Right
Pressure control
When the hydraulic gets beneath the pressure (value) set point tolerance the proportional valves will be opened and the pump will start.
135 bar 125 bar 115 bar
Movable Roller
Press cylinder
This will remain so until set point operation pressure tolerance has been reached. After this the valves will close again and pump will stopped. In this example on one side.
V 09
V 08
V 10 20 m Amp
V 05
V 06
18,4 m Amp
80 %
Characteristics proportional valves.
V 1/2 V 3/4 100 % V 07
12 m Amp 0%
80 %
100 %
Pump 28 HD 41 M 01
Proportional valves
The proportional valves act in two flow directions which are activated by two solenoids: a) Pressure increase: Analogue PLC output: 12 - 20mA corresponding to 0 - 100% opening b) Pressure decrease: Analogue PLC output 12 - 4mA corresponding to 0 - 100% opening The neutral position (both ways closed is determined at I = 12mA ). The activation of the solenoids is organised via valve amplifier installed on top of the proportional valve.
20 m Amp
18,4 m Amp
80 %
Characteristics proportional valves.
100 % V 1/2 V 3/4
V 07
12 m Amp 0%
80 %
100 %
Pump 28 HD 41 M 01
45
4 m Amp
46
Fixed Roller
Gap = 10 mm
Set points
Distance pieces
L 0mm
0 mm ( Bearing distance )
Right
This is the point where the bearing distance is 0. For the gap measuring this point is 4 m Amp. The bearing blocks are fixed in a way that the rollers can never touch each other physically
L min
Fixed Roller Left Gap = 25 mm Movble Movable Roller Roller Right
15 mm ( Bearing distance )
Distance between the bearings used as lower limit for the pressure control. If distance is less pressure control will be deactivated. GAP < L min Pressure control OFF GAP > L min Pressure control ON normal operation
47
48
Start program BCON (RP GROUP = START)
With the group Roller Press start command both pressure decrease valves are energized to allow the movable roll to move backwards. This is important after a restart following an emergency stop with uncrushed material above the rolls. Is the bearing distance left or right <L3 the movable roll will be moved using the retraction cylinder until one side has reached L3 The retraction cylinder then is deenergized.
49
Start program BCON Program Step 1 and 2
BCON Program Step 1 If the bearing distance left or right is L3 or after a delay time the start of the roller drives in parallel mode or sequential mode is performed.
The movable roll will be moved towards the fixed roll by energizing both pressure increase valves, when both roller drives are in operation and the run-up time is elapsed. Both pressure increase valves are to be controlled independently.
Exceeds any hydraulic pressure the limit 40bar the group start sequence will be stopped with alarm.
49
Start program BCON Program Step 3
BCON Program Step 3
The program BCON stops and the shut-off gate opens when the bin level reaches the maximum limit set at SCADA, e.g. 50% and the pressure control function is activated in case the operation mode "AUTOMATIC" is selected. The delayed energising of pressure reducing valves takes place when the shut-off gate is closed. This causes the movable roll to move apart from the fixed roll. This action is terminated when the bearing distance has reached the limit L3 or latest after 5 sec. Now, the movable roll will be positioned to the limit L2 (start position) using the pressure increase valves.
51
Left Fixed Roller Gap = 35 mm
Set points
Roller distance 10 mm + L2 Bearing dist. 20 mm = Gap 30 mm L min L2
Parameter set in the PLC. Set only once. Range from 5.0 to 30.0 mm Actual set point 20 mm
Right
Movable Roller
Left
Right
Movable Roller
52
Set points
Left
Fixed Roller Normal operation Gap = 65 mm maximum Movable Movable Roller Movable Roller Movable Roller
Right
L min L2 + 10 mm
Limit switch
Maximum distance allowed between the bearings. ( 65 mm Gap ) Determined by a mechanical switch. Over 65 mm gap the roller press will stop with max. gap alarm.
53
Normal Stop of the group Roller Press
This command starts the shut-down procedure with: stopping of the feed belt, the pressure reduction by opening of the pressure reducing valves until the limit L3 has been reached or for max. 5sec, the run-off of the roller drives for 1min. This procedure can be released by: STOP command from SCADA Drive fault Instrument loop fault Over temperature roller bearings Over temperature gear box bearings Over temperature hydraulic oil Disturbance BCON
54
Fast stop of the group Roller Press
This command stops the group Roller Press immediately stopping the feed belt, Stop of the roller drives and all other drives of the Roller Press, de-energising of the hydraulic valves. This procedure can be released by: EMERGENCY STOP command from the local control panel Loss of control voltage Activation of the movable roll end position Hydraulic pressure >180bar Under speed monitoring of any roll Fault of any roller drive
55
Group Aux. Heater = Start / Stop
The commands Start/Stop and LOCAL are sent from SCADA to the ROLCOX system. This signal starts the heating system for the grease pipe and oil pipes. The heating units are self-controlling. No temperature control is required in ROLCOX.
3212LQ5.H01
3212LQ5.H02
3212LQ5.H03
56
Left Fixed Roller Right
Current control
By means of to much adjusting of operation pressure or due to changing material properties the electrical load of the main drives can become to high. If this load exceeds a preset maximum the pressure will be reduced.
Movable Roller
Press cylinder
V 09
V 08
V 10
V 05 10
V 11 06
This will last until the movable roller reaches L2 + 10 mm = 45 mm gap or until the drives get below operation load.
V 1/2
V 3/4
V 07
57
Fixed Roller Fix Roller Left Right
RP Group stop
At a stop of the roller press (desired or undesired) the RP - slide gate will close and stopped the material feed to the RP. The Pressure decrease valves will open, the proportional valves will open,and the emergency valve will open.
V 10
V 09
09 V 08
V 05 10
V 06 11
The rollers will due to material pressure move apart until L2 is reached on both sides or after time limit. Roller press will stop after 60 sec.
V 1/2
V 3/4
V 07
Pump 28 HD 41 M 01
The Pressure decrease valves will close, the proportional valves will close, and the emergency valve will open.
58
ROLCOX Parameters
59
OPERATION CURRENT Adjusting range: 70 ... 90% of the nominal current In
SCADA
This value corresponds to the upper limit of the standard operating current. As soon as that value is reached, the overload pressure reliefing measure is terminated. This value corresponds to the upper limit of the standard operating current. As soon as that value is reached, the overload pressure reliefing measure is terminated.
In case the current difference between the drives exceeds the set limit, an alarm will be generated without further consequences for the operation of the Roller press.
60
SCADA
With activated gap-dependent pressure control, the SETPOINT PRESSURE is limited to the sum of OPERATING PRESSURE + PRESSURE INCREASE MAX. An internal pressure limit (150 bar) cannot be exceeded! With activated gap-dependent pressure control, the SETPOINT PRESSURE is limited to the sum of OPERATING PRESSURE + PRESSURE INCREASE MAX. An internal pressure limit (150 bar) cannot be exceeded! With activated gap-dependent pressure control, the SETPOINT PRESSURE is limited to the sum of OPERATING PRESSURE + PRESSURE INCREASE MAX. An internal pressure limit (150 bar) cannot be exceeded!
60
SCADA
62