Alta Solutions

AS-240 GrinderMon™

Roll shop operators do not have sufficient information to recognize many grind problems that lead to mill chatter and back-up roll printing. These subtle roll surface variations result in reduced mill productivity and poor product quality.

AS-240 GrinderMon™ provides advanced monitoring of the roll grinding process. For the first time, roll shop operators can dramatically reduce hidden roll surface imperfections. The impact on mill performance is significant.

A recent study by a major steel manufacturer documented the following impact on mill performance upon installation of AS-240 GrinderMon™:

  • Unscheduled backup roll (BUR) changes were eliminated
  • 7% mill production increase
  • $300,000 in direct cash savings (on one grinder, in one year)
  • Payback in less than two months

AS-240 GrinderMon™ provides real-time feedback for roll shop operators and managers to see the vibration signature being transcribed onto the rolls. Alarm limits can be set to control the acceptable vibration values during the different parts of the grinding cycles.

The system interfaces with the grinding controls to obtain roll parameters (diameters, depth of cut) and operating parameters (wheel load, traverse, normal force, overlap ratio, and aggressiveness). Grinding process data is automatically saved by roll ID and a summary page is printed for quality control documentation.

How much are hidden roll grinding defects costing you?

Benefits

  • Prevent mill chatter and speed reductions
  • Improve product quality and finish
  • Avoid backup roll printing
  • Reduce gage variation

Features

  • Real-time grinder quality feedback
  • Records complete grinding session
  • Multiple concurrent displays for operator, shop manager, and reliability personnel

Documentation

Press Releases and Articles