- Force Measurement
- RollKraft
Rolling Force Measurement in Hot and Cold Rolling Mills
Precise rolling force measurement for hot and cold rolling mills. Find out how the IMS RollKraft Circular and IMS RollKraft Rectangular optimize process control, AWC control, product quality and equipment protection.
Rolling force is one of the most important process variables in modern hot and cold rolling mills. Whether in hot strip mills, cold rolling mills, tandem mills, plate rolling mills or section rolling mills: the forces acting during the rolling process directly influence product quality, process stability and production efficiency.
Precise rolling force measurement provides the basis for reproducible rolling results and efficient process control. The measurement data obtained is used, among other things, for automatic gauge control (AGC), automatic width control (AWC), roll gap control and continuous equipment monitoring.
At the same time, high rolling forces, dynamic loads, vibrations, temperature fluctuations, water and scale place the highest demands on the measurement technology used. Modern load cells must therefore deliver reliable and reproducible measurement results even under extreme rolling mill conditions.
bis zu 2.200
Tonnen
Breitenreduktion von bis zu 350 mm
Challenges in Rolling Force Measurement
Measuring rolling force in hot and cold rolling mills places high demands on the sensor technology used.
High Rolling Forces
In modern rolling mills, forces ranging from several hundred to several thousand tonnes act on the material being rolled. These loads require particularly robust and precise measurement systems.
Dynamic Loads
Short load changes and fast control processes require high signal dynamics and powerful signal processing.
Extreme Environmental Conditions
Rolling mills expose sensor technology to numerous influences:
- Vibrations
- Temperature fluctuations and high process temperatures
- Water and cooling media
- Rolling emulsions and oil
- Scale and contamination
- Permanent mechanical loads
The measurement systems used must deliver reliable and reproducible results even under these conditions.
Direct Rolling Force Measurement with IMS RollKraft
For applications in hot and cold rolling mills, direct rolling force measurement has become established as a particularly precise method. Examples include the IMS RollKraft Circular and the IMS RollKraft Rectangular, two high-precision load cells specifically developed for the requirements of modern rolling mills.
Unlike conventional solutions that determine rolling force based on hydraulic pressure or other substitute variables, both systems measure the actual force directly in the force path. This minimizes measurement uncertainties and provides significantly higher accuracy for process control.
IMS RollKraft Rectangular
The IMS RollKraft Rectangular was specifically developed for applications where design requirements or available space require a rectangular design. It offers the same high measurement accuracy and reliability as the Circular version and is suitable for a wide range of rolling mill and metal processing applications.
Technological Features
The RollKraft Rectangular combines high-precision strain gauge technology with a robust mechanical design.
Key features include:
- Direct rolling force measurement in the force path
- High-precision strain gauge technology
- Rectangular design for flexible integration options
- High reproducibility and long-term stability
- Robust design for extreme loads
- Integration into existing automation and control systems
Use Under Difficult Environmental Conditions
The RollKraft Rectangular has also been developed for operation under demanding rolling mill conditions:
- High mechanical loads
- Dynamic load changes
- Strong vibrations
- High temperatures
- Water, oil and emulsions
- Scale and contamination
This ensures reliable force measurement over the long term, even under extreme operating conditions.
Advantages over Pressure-Based Measurement Methods
By directly measuring the rolling force, the RollKraft Rectangular offers the same advantages as the Circular version:
- Direct measurement of the actual rolling force
- Higher accuracy
- Improved control performance
- Optimization of AGC and AWC systems
- Reduced process fluctuations
- Improved product quality
Installation and Integration
The same basic principles apply to installation as for the RollKraft Circular:
- Complete transmission of the rolling force through the sensor
- Positioning as close as possible to the roll gap
- Avoidance of bending, lateral and torsional forces
- Use of a flat and torsionally rigid mounting surface
Through complete integration into the mill stand structure, ease of maintenance is preserved and roll changes can be carried out without additional measures.
IMS RollKraft Circular
The IMS RollKraft Circular is a high-precision load cell with a circular design, specifically developed for use in hot and cold rolling mills.
Technological Features
The IMS RollKraft Circular is based on modern strain gauge technology and has been designed for continuous operation under demanding rolling mill conditions.
Key features include:
- Direct rolling force measurement for maximum measurement accuracy
- High-precision strain gauge technology
- Robust mechanical design
- High-strength stainless steel construction
- High long-term stability and reproducibility
- Temperature-compensated measurement technology
- Easy integration into existing measurement and automation systems
Use Under Difficult Environmental Conditions
The RollKraft Circular is specifically designed for operation under the following conditions:
- High dynamic loads
- Extreme rolling forces
- Strong vibrations
- Temperature fluctuations and temperature extremes
- Water and cooling media
- Oil, emulsions and scale
- Continuous operation in an industrial environment
This enables the system to provide precise and reproducible measurement values even under harsh production conditions.
Advantages over Pressure-Based Measurement Methods
The main difference compared with conventional methods is the direct measurement of the actual force acting on the system.
This provides operators with:
- Higher measurement accuracy
- Faster responses from control systems
- Improved AGC and AWC control
- Reduced scrap
- Higher productivity
- Greater transparency of the rolling process
Installation and Integration
For precise force measurement, the entire rolling force must be transmitted through the load cell. The sensor should be positioned as close as possible to the roll gap in order to minimize structural deformation and parasitic force paths.
The mechanical design should primarily transfer compressive forces to the load cell. Bending, lateral and torsional forces should be avoided as far as possible.
A proven installation solution is to install the load cell below the bearing of the lower backup roll. This keeps the load cell fully integrated into the mill stand structure and does not interfere with roll changes.
IMS RollKraft 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 RollKraft Controller (MMV, Modular Masurin Amplifier) serves as the central interface between the RollKraft 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 conditioned by a fixed preamplifier and then digitized. Complete signal adaptation is software-based and therefore fully digital. This considerably simplifies parameterization and provides a high degree of flexibility when adapting the system to different equipment and process requirements.
Flexible and Modular System Design
The standard RollKraft Controller features two input channels for IMS RollKraft load cells. Thanks to its modular design, the system can be expanded by up to two additional input channels if required, without affecting processing speed.
This makes the measuring amplifier suitable both for new installations and for modernizing existing upsetting presses and rolling mill equipment.
Seamless Integration into Automation Systems
For connection to existing control and supervisory systems, the MMV provides various communication options:
- ±20 mA analogue outputs
- ±10 V analogue outputs
- Fieldbus connection optionally available
- EtherCAT support
- Profinet support
- 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 even into installations without a fieldbus infrastructure. This makes the RollKraft Controller an excellent replacement for older electronic units.
A particular advantage is that existing IMS load cells can continue to be used. In many cases, extensive mechanical modifications or replacement of the sensor technology are not required.
Fast Commissioning and Convenient Operation
The RollKraft Controller is housed in a robust stainless steel enclosure measuring 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 preconfigured, significantly reducing the effort required for on-site installation.
Advanced Diagnostic and Configuration Options
The RollKraft 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 allows maintenance and service work to be carried out efficiently and system configurations to be tracked at any time.
The Ideal Addition to IMS RollKraft Load Cells
In combination with the RollKraft Circular and the RollKraft Rectangular, the RollKraft Controller forms a powerful overall system for direct rolling force measurement in hot and cold rolling mills. While the load cells directly measure the actual rolling forces in the force path, the controller provides precise signal processing and reliable provision of measurement data 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.
do you have any questions?
#IMS Expert
Uwe Fliegenschmidt
Reserve your personal consultation appointment now!
Choose between a scheduled call back, a Teams video conference or simply use our contact form.
We look forward to hearing from you!
IMS KraftSeries measuring systems for Force Measurement
EdgerKraft
Explore the product range
StripKraft Looper
Explore the product range
StripKraft
Explore the product range