REPRESENTATION OF FLYING

SHEAR C PROGRAMME AS
ALGORITHMS

LMMM at a glance
Breakdown mill Input: 320*250mm 6m length bloom from SMS

Output : 125*125mm 32m length Billet

Bar mill Input : 125*125mm 30m length Billet

Output : Plain Bars and Rebars, Angles, Channels etc...

Two Walking beam Furnaces.
Break down mill is a 7 stand rolling mill.
Flying Shear is used for cutting the billet into desired lengths.
10m Billet goes to Wire rod mill and 30m Billet goes to Bar mill for
further size reduction.
Bar mill is a three stage mill.

Roughing train is a two strand mill consists 8 stands

2 Intermediate trains each consists 5 stands
2 Finishing Trains each consists 4 stands with loopers
Two cooling beds
7 Strapping machines for two lines(Machine 7 is spare)

PURPOSE OF FLYING
SHEAR
To

cut Head & tail ends of the billet

To perform Part length cuttings of Billets

to the desired length
To perform emergency cutting of Billet
into 5 or 8m

POWER CIRCUIT

11KV

405KVA
11KV/325V

6KVA
415/400V

T1050 N2400

SHEAR FORCE: 2100kN

KNIFE CIRCLE: 800mm dia
GEAR RATIO
: 5.136
OPERATING MOTOR SPEED:0-280rpm
KNIFE SHAFT SPEED: 0-54rpm

HSCB 292KA
DC CONTACTOR

186KW,230V,884A,435rpm
230V,8.8A

186KW,230V,884A,435rpm
230V,8.8A

LOCATION OF FLYING
SHEAR

PHASES OF THE SHEAR

REST POSITION/BASIC POSITION
ACCELERATION

DECELERATION

OUT MAT POSITION

IN MAT POSITION

SEPARATING POSITION MATERIAL DIRECTION

LEADc

IO N
RAT
ELE

d
DEC

A
C
C
EL ER
A
T
I
ON

V
O
L
T
A
G
E

TIME

AUTO MODE

Phases of the Shear:

0
+33

ACCELERATION

REST POSITION/BASIC POSITION

-33

DECELERATION

OUT MAT POSITION

IN MAT POSITION

+500

-500MATERIAL DIRECTION

ALGORITHM IN BLM1
Main function has 2 sub functions:
1. EventDispatcher
2. AuxRefValue Gen

EventDispatcher:
Billet enter stand 3:
Executes only when
1. Stand 3 should be running
2. Stand 3 current should be high and stable
3. Billet in stand3 should be in reset state.

Algorithm for billet enter stand3:

1. Set billet entered stand 3.
2. Reset billet left stand 3.

Billet leave stand 3:

. Executes only when
1. Stand 3 should be running
2. Stand 3 current should be high and stable
3. Billet in stand3 should be in set state.

Algorithm for billet leave stand3:

1.From st3 billet time stand 3 billet length is
calculated

(ST3_BILLET_LEN) =
(MAX_STAND3_SPEED/MAX_VOLT_LEVEL_COUNT) *
STAND3
REFERENCE * ST3_BILLET_TIME/1000

2.Expected stand 7 length is calculated

Expected Length at Stand7 = ST3_ST7_REDUCTION *
ST3_BILLET_LEN

3. Cut lengths are calcuted according to the

mode selected and are stored in cutpattern
register.

Check if stand 7 billet length is greater

than minimum billet length (26.0 m), if
yes, then
material length= st 7 billet length
If no, then
material length= nominal billet
length(32m)

If operator selects bar mill mode then operation mode is bar

mill (1).
If operator selects sales length mode and auto tail cut is not
selected then operation mode is sales length (2).
If operator selects sales length mode and auto tail cut is
selected then, Calculate rest length in auto head cut selection
using

Calculate rest length without auto head cut selection using

If calculated rest length in the above case is greater than

maximum tail length (0.5 m), then operation mode is 3 equal
lengths (3) otherwise sales length (2).

If operator selects WRM mode, then add 1 to the

count of WRM blooms (only for display) and check the
condition.
if MaterialLen < = TotalWRMMateriallen /* 32.7m */
If true then operation mode is WRM (4).
Else operationmode is 3 equal lengths (3) and add 1
to the count of over length blooms (only for display).
If operator selects bar mill mode and there is some
fault in bar mill or selects3 equal lengths mode then
operation mode is 3 equal lengths (3). 3 equal lengths
mode is the default mode.

cut pattern is used to store the pattern in which cuts

are being given for bar mill mode head length is
stored in cut pattern[0], material length in cut
pattern[1], tail length in cut pattern[2]. Cut pattern
can store 5 different values from cut pattern[0] to
cut pattern[4].

Billet enter stand 7:

cut pattern pulses are calculated using cut pattern
lengths
Calculate cut pattern pulses corresponding to head
length using

Calculate cut pattern pulses corresponding to part lengths

(for all parts separately) using

If auto tail cut is selected then calculate cut pattern pulses

corresponding to tail length using

Billet leave stand 7:

Reset billet entered stand 7.

Billet reach PC210:

set billet reach PC210.

Billet leave PC210:

Calculate actual length of billet at stand 7.
Check if
If yes calculate new reduction factor

Calculate change in reduction

If calculated delta reduction is greater or less
than max delta reduction(0.05) new reduction is
again calculated using maxdelta reduction
Average of new reduction and prev st3st7
reduction is taken as new reduction factor.

Signals transferred using Ethernet Global Data from

BLM1 to BLM2:

WRM mode selected information to BLM2 PLC from BLM1 PLC.

Head cut for current billet is selected.
Tail cut for current billet is selected.
Start chop 5m signal.
Bar mill selected for the current billet information.

Signals transferred using Ethernet Global Data from

BLM2 to BLM1:
Stand 7 current higher than threshold value.
Photo Cell 210 signal status.
Stand 3 current high and stable.
Flying Shear is enabled for cutting.
Bit to initiate pulse calculation for shear operation.

BLM2 FUNCTIONS

BLM2
Main function includes two sub functions:
1.
Eventdispatchter
2.
Compute shear speed

Algorithm of event dispatcher:

.
Calculate MR pulses corresponding to 1 sec when PC210 is high and hence
st7 mat speed
St7 mat speed= MR CTB* set head cut cali value
. Calculate

shear reference w.r.t mat speed, for the purpose of feedback using

. Calculate

shear ref at in mat position with cutting lead

Billet reach PC210:

Initialize cut counter and st7 accum count
reach PC210 to 0.
Calculate new shear lead factor based on
operator input

Calculate next cut pulses= st7 accum count

reach PC210+ cut pattern pulses

Billet leave PC210:

Initialize st7 accum count
tail cut extra lead should be 0 and 5
Calculate lead factor corresponding to tail cut

If tail cut is selected

If WRM is selected the billet cannot be more than max WRM

length

FUNCTIONS
Compute Shear Speed:
ACCELERATE SHEAR:
This sub function controls acceleration of shear
from basic position to cut completed position.
CUT COMPLETE: Called from accelerate shear
function when cut is completed.
1. Reset shear knives entered material.
2. Increment cut counter
3. Calculate next cut pulses

Calculate shear velocity

Braking control:
Calculates shear speed proportional to sqaure
root of diatance to braking positon
This includes both braking and position control
This function is executed until signal for cut
initiation is available.

THANK YOU