Morgan High Speed Pinch Roll and Laying Head

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Morgan High Speed Pinch
Roll and Laying Head
For increased production, improved yield and consistent
product quality
Answers for industry.
Providing the highest operating speeds
Your challenge:
Our solution:
The high-speed pinch roll and laying head system plays a
crucial role in the production of high-quality rod. That‘s
because, on the one hand, speed is an essential factor for
productivity. At the same time, however, the coil must be
well-formed and correctly positioned on the conveyor.
This calls for precise control and accurate coordination of
the pinch roll and laying head speeds.
Designed for sustained high-speed operation, the Morgan
High Speed Pinch Roll and Laying Head system has set
new standards – and works with extreme precision and
reliability. The new laying head arrangement incorporates
an integral segmented deflector plate for front and tail
end control, and a rugged gear box with oil film or roller
bearings for reduced vibrations, all to allow for longer,
less wearing pipe paths.
The pinch roll and laying head must also be variable
enough to adapt to your requirements for product size
range and production rates.
In addition, the wear components need sufficient life to
minimize production interruptions.
The optional use of multiple pipe supports in the laying
head provides a means of efficiently covering all products,
in either clockwise or counterclockwise rotations, all with
front and tail end control. Together with the latest design
turndown, the laying head can process even scratchsensitive grades with optional interchangeable vertebrae
and rollerized pipe supports. The laying head pipe support
can be changed in less than 15 minutes, minimizing the
impact on mill operations.
Our system offers greatly improved flexibility and
minimized change times, thanks to the new laying head
pipe support design and pinch roll units that can be
traversing. In addition, the Morgan High Speed Pinch Roll
and Laying Head are designed for rolling a wide range of
finished rounds from 4.0 to 26.0 mm.
For high-speed rolling of small sizes, a revolutionary
laying head upgrade with extremely long life has been
recently developed. This new durable pipe technology
results in significant reduction in downtime and achieves
predictable, reliable production.
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Our innovative design and pioneering technology enable Siemens VAI
Metals Technologies mills to perform consistently and reliably at the
highest possible day-to-day operating speeds.
Advantages of Morgan High
Speed Pinch Roll and Laying
Head:
••Intelligence built in – The
patented Morgan Intelligent Pinch
Roll and customized mechatronics
package provide repeatable, errorfree operation over the entire
range of sizes in a self-regulating
system that minimizes operator
input.
••High quality at high speed – The
operating speeds are the highest
on the market. The tail end control
reduces oversized and distorted
tail end rings of small sizes. At
the same time, a well-defined and
consistent ring pattern on the
conveyor helps achieve uniform
metallurgical properties.
••Record-setting pipe life – With
the SR Series™ pipe optional
upgrades, laying head pipe life in
excess of 130,000 tons has been
demonstrated on small diameter
products rolled at high speeds.
••Large diameters welcome –
The Morgan High Speed Laying
Head provides improved product
quality for all larger sizes. Here,
the wobble control helps reduce
the coil height – facilitating coil
stacking and shipping.
••Flexible options available –
Interchangeable vertebrae and
rollerized pipe features available
for surface-sensitive grades; twin
pipe design available for producing
different coil dimensions for
different product sizes; all options
easily controlled with mechatronic
packages.
••No need to bend your own pipes
– Bending services are available to
provide your mill with ready-to-use
pipes.
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Morgan High Speed Laying Head for consistent high speed operation
Morgan High Speed Pinch Rolls are durable and reliable
Improving the ring pattern
The Morgan High Speed Pinch Roll and Laying Head
design with the integral segmented deflector plate helps
improve the ring pattern on the conveyor for both small
products at high speeds and large products at lower
speeds. These systems allow operators to increase
production, improve yield, and ensure consistent product
quality, while reducing delays at the reform station.
High speed – day after day
Our customers state that the high-speed pinch rolls and
laying head are a critical area of rod mill equipment. Our
innovative design and pioneering technology has enabled
Siemens VAI Metals Technologies mills to perform
consistently and reliably at the highest day-to-day
operating speeds possible.
The latest SR Series™ laying head upgrade has been
proven to improve ring pattern on small sizes at high
speeds and to do that consistently. This results in smooth
operation on the Stelmor® conveyor, more uniform
cooling, improved rod coil quality and increased
production through reduced downtime.
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Other pinch roll units in our mills, notably intermediate
pinch rolls, provide a flexible system with mechatronics
for upstream mill processes.
A new turndown design with extremely long life is now
available to further extend time between changes of those
parts to more than 200,000 tons on small sizes at high
speeds.
Morgan High Speed Pinch Roll and Laying Head arrangement
Traversing pinch roll between water boxes
Mechatronic package
The success of the Morgan High Speed Pinch Roll and
Laying Head system is ensured with a mechatronics
package, which provides closed loop control of pinch force
using servo control technology and pinch roll drive
speeds. The laying head control reliably shapes coils of a
specified diameter with repeatable front end positioning,
and coordinates speeds with pinch rolls for precise
positioning and smooth operation. This self-regulating
system minimizes user input and set up with monitoring
and controls managed through an easy-to-navigate
human machine interface (HMI). The HMI allows both fine
and wobble adjustments to the laying head’s rotational
speed.
Morgan Pinch Roll and Laying Head in a new high speed rod mill
The mechatronics package can be fully integrated into the
standard SIROLL LR solution for the rolling mill.
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Upgrades available for existing laying heads
Several options to dramatically improve your rolling of
small products at high speeds are available to meet your
budget and needs.
••SM1 – Self-regenerating basic pipe
••HT1 – Self-regenerating treated pipe
••CM3 – Self-regenerating composite pipe
••DM2 – Self-regenerating pipe with proprietary core
material for maximum performance
Innovative turndown design dramatically extends time between changes
140,000
Finished product (tons)
Laying head upgrade results in excellent ring patterns
120,000
100,000
80,000
60,000
40,000
20,000
Features of this new technology include:
••Unmatched production levels – Eliminate pipe changes
during normal small product rolling campaigns
••Improved head and tail ends – Greatly improve
consistent formation of head and tail ends
••Excellent ring pattern – Predictable results with
consistent ring spacing
••Easy retrofit – Seamless transition to replace older
laying head arrangement
••Reduced maintenance costs – Longer life on
turndowns, laying head bearings and pipes
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Standard
SM1
HT1
DM2
Comparison of expected pipe life on small diameters (US tons)
Main benefits of the new SR Series™ upgrades:
••Record results in performance
••Vibration challenge eliminated
••Improved laying pattern
••Unmatched pipe life
••Easy retrofit for existing systems
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CM3
Pipe type
Excellence from experience
Selected success stories with Morgan High Speed
Pinch Roll and Laying Head systems
Quality products at high speeds
Customer:
Zenith Steel, Changzhou, PRC
Plant type:
High speed rod mills
Our solution: Provide two rod outlets, each with Morgan Vee Mini-Block
Pre-Finishing mills, Vee No-Twist® Mill, water boxes,
Morgan High Speed Pinch Roll and Laying Head system,
Stelmor® conveyor, reform and compactors for high
production capability.
Technical data: 105 m/s maximum finishing speeds, 150 tph maximum production rate, rod sizes 5.5 – 20.0 mm, rebar
sizes 6.0 - 16.0 mm
The result:
The new rod mills are equipped to produce carbon steels, welding wire, cold heading, spring, bearing, tire cord and PC strand
Broader product range, higher quality
Customer:
Votorantim Metais, Resende, Brazil
Plant type:
Single strand rod mill (future two strand)
Our solution:
To help meet the needs for a high-production rod mill rolling rebar in coil, a series of Morgan High Speed Pinch
Rolls were located between water boxes after a 10-stand
No-Twist Mill, followed by a Morgan High Speed Pinch Roll
and Laying Head system.
Technical data: 110 m/s maximum finishing speeds, 130 tph, plain rod
from 5.5 – 24.0 mm, ribbed rod in coil from
6.3 – 12.5 mm, plain carbon steel
The result:
The new rod mill provides capability for expanded product size range and quality.
Pipe life reaches record levels
Customer:
Sterling Steel, LLC, Sterling, Illinois, USA
Plant type:
Single strand wire rod mill
Our solution:
Replace the existing laying head pipe with the new
SR Series™ DM2 pipe.
Technical data: Plain rod sizes 5.5, 6.35 and 7.94 mm with maximum finishing speeds up to 100 m/s
The result:
The new pipe design results in record pipe life, rolling at
higher speeds with a better coil package.
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Competence Centers
Siemens Industry, Inc.
50 Prescott Street
Worcester, MA 01605-2615, USA
Phone: +1 508 755-6111
Siemens S.p.A.
Industry Sector Metals Technologies
Via Luigi Pomini, 92
I-21050 Marnate (VA) Italy
Phone: +39 0331 741211
E-mail: [email protected]
Headquarters
Siemens VAI
Metals Technologies GmbH
P.O. Box 4, Turmstrasse 44
4031 Linz, Austria
Phone: +43 (0) 732 6592 - 0
Order No. E10001-M3-A322-V1-7600
Dispo No.: 21661 K-No.: 20254 | Printed in USA
© 06.2013, Siemens VAI Metals Technologies GmbH
The information provided in this brochure contains merely general
descriptions or characteristics of performance which in actual case of
use do not always apply as described or which may change as a result
of further development of the products. An obligation to provide the
respective characteristics shall only exist if expressly agreed in the
terms of contract.
All rights reserved. Subject to change without prior notice.
Stelmor and No-Twist are registered trademarks of Siemens Industry, Inc.
SR Series is a trademark of Siemens Industry, Inc.

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