The first step includes an upgrade of the existing ABB 800xA process control system 5.1 to the latest version, as well as the implementation of an AC800 PEC controller as a master encoder and for drive control in an existing ABB system based on MP200 controllers from the mid-1990s. The AC800 PEC controller is specifically used for the demanding drive-oriented control and regulation tasks in all types of rolling mills. At the same time, the application software has been updated to the latest technology and a current diagnostic system implemented.
In connection with this, a virtualized client/server architecture is used, promising significant savings in terms of the hardware deployed. The challenge here is a very short rebuild time during system downtime at the turn of the year 2016/2017.
As a result of updating to the new 800xA platform, state-of-the-art ABB rolling mill function libraries will be implemented to improve general performance.
These include features such as:
- Optional interstand tension control via roll gap
- Decoupling loops to compensate interactions
- Adaptive speed feed-forward
- Interstand speed estimation
- Optional inverse model for parameter identification / adaptation
- Fast optical link communication between controllers