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Performance Optimization Service for cold rolling mills

Advanced service combines digital technology with real-time continuous monitoring and remote expert support to achieve as yet unprecedented levels of product quality, yield and productivity in all types of cold rolling mills

Data is collected in real-time from data acquisition systems, such as IBA, or from process controllers via OPC or Modbus/TCP. It is seamlessly integrated with process control and is securely stored onsite at the customer facility using ABB Historian. Information is then visualized in intuitive dashboards which designated site and ABB personnel can access online 24/7.

The digital technology at the core of this service - ABB Ability™ Data Analytics for cold rolling mills* - employs cold rolling mill-specific algorithms. This allows you to harness high level plant and process data and use it to reveal trends and inter-relations between various process parameters, trace and visualize the KPI’s important to your cold rolling mill, right down to individual coil or coil set.

Real-time continuous monitoring and remote expert support allow to detect and analyze deviations, identify their root cause and leverage the insights gained to predict and prevent faults before they affect production.  The service includes proactive deviation alerts and reports, as well as system maintenance and updates -  ensuring smooth, reliable operation and faster, more data-driven decisions. Insights can also be leveraged across multiple sites to unlock further cost savings at enterprise level.

*ABB Ability™ Data Analytics for cold rolling mills is available as part of Performance Optimization Service for cold rolling mills or as a stand-alone product.

This service is delivered via the ABB Ability™ Collaborative Operations for metals platform, offering continuous monitoring and expert, remote support designed to help you reach higher levels of performance optimization.

Curious about how much value this offering can unlock for your cold rolling mill?

Connect with our experts to find out more

Use case from a 20-high cold rolling mill reference

Thickness quality analysis

Sampled 3 days of customer iba data, total 56 coils with initial thickness of 2500 µm-5280 µm & final thickness 600µm-2970µm, compared with results from ABB benchmark 20-high cold rolling mill to identify improvement potential. Direct comparison difficult due to lack of info on the alloy & thickness control i.e. AGC filter times, or general mill behavior & limitations

Productivity comparative analysis

Optimal coil based on best times for threading, unthreading, reversing time, rolling speed & one-time acceleration & deceleration instead of stepped speed change. Results from 56 analyzed coils shows 53% production loss compared to optimal rolling & 21mins more production time for actual coil vs optimal coil

Improvement areas identified

Very long coil preparation & threading times were regularly observed & reversing times between passes were inconsistent & often long; potential for improving threading & reversing times. Overshoot & undershoot deviations as well as delay in reaching final target thickness were often detected; potential for improving off-gauge length at the strip head

What can you achieve with Performance Optimization Service for cold rolling mills?

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