İÇDAŞ Steel, the third largest long product producer in Turkey, upgraded the shear control system for the bar mill #3 and #4 two-strand wire rod mill. Each mill is fed by a 120 ton/hr reheat furnace and the two mills have a combined production capacity of 1.4 Mtpy. Russula supplied the shear upgrade solution and on-site assistance.
Poor shear performance substantially affects mill operations. In order to achieve an efficient process, the correct selection of hardware and configuration of shear control software is paramount. Different placement in the mill and functionality mandate the proposal of distinct automation solutions to optimize the bar mill and wire rod mill processes.
Stemming from a wealth of knowledge and experience in shear upgrades, Russula proposed replacing the current shear control Siemens FM453 PLC modules with SIMOTION. This Siemens motion control system was configured for the existing shears, resulting. Since the current control systems were Siemens Step 7 or Step 5 platforms, SIMOTION provided a flawless integration into İÇDAŞ’s current control system.
Each mill has 4 shears. Russula provided the Simotion equipment, software engineering, installation supervision, commissioning and production support necessary for İÇDAŞ to upgrade the shears and improve mill operations. Two cabinets were supplied to upgrade the eight shears, one with 3 Simotions for the bar mill shears and the other with 2 Simotions for the wire rod shears. Eight new encoders for the shear knife shafts were also supplied.
Start/stop rotary shears require very accurate blade position control to assure high precision and reliability. As such the Simotion merged motion control, logic, and additional technological functionalities, which eliminated the historic separation between pure logic functions, motion control functions, and technology functions. In essence the time critical interface between the multiple components was no longer required, which made the İÇDAŞ system more uniform, especially important for the wire rod mill's shears with high speed control.
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