1. Feature of MH Plant Controller（MHPC-M）A variety of controllers are realized by using a highly performance sequencer

MELSEC (Made by Mitsubishi Electric) as a base.

1) Hydraulic cylinder control of MillHOT Tandem Mill、SKP、Edger etc

2) Hydraulic cylinder control of Down CoilerUF、MD、SG、MD

3) ORP（Online Roll Profiler）4) Process Line strip stabilizer5) Roll Eccentricity Controller6) Image Processing Equipment

HOT FM Strip Center Position DetectorProcess Line Coil Fishtail Detector

Realization of a variety of controllers

４

1) Data gathering equipmentThe simple version collectable to a notebook PC to the type which can collect mass data offers the equipment according to a use.

2) Response measuring equipmentA Step response and frequency responsemeasurement are possible.

Lineup of adjustment support equipment（Option）

３

1) Improvement of OperationSince all the operations can carry out on a screen, operation becomes easy.

2) Flexible screen creationSince creation of a screen is easy, the screen creationaccording to a request of the customer is possible.

Operation unit (Touch Panel)

２

1)High-speed operation processing.1msec is realized as an operation cycle of position feedback control (2Loop).

2)Variegated Interface.Selection of Interface according to a situation is possible for FL-NET, Ethernet, etc. as an interface with Line PLC.

3)Improvement of MaintenanceSequencer which has spread widely is used andmaintenance is performed. And future updating is easy.

The high performance Sequencer MELSEC

１

ContentsItemNo

1980 1990 2000 2010

MPC-16A

MPC-32A

MHPC-M

100

300

0

200

Number of deliveries

2. Delivery record

3. Specification comparison of Controller

System consists of MELSEC.Special equipment (image processingetc.) is interface at Ethernet.

A system configuration includes the own making Board of standard bus specification (MULTIBUSⅡ) in Fuji Electric PLC.

A system configuration connects peripheral equipment, such as an I/O board, to a CPU board by a flat cable.

Feature

Touch Panel(Mitsubishi Electric)

FC-9801(NEC)FC-9801(NEC)Operation unit

FL-NETEthernet etc

P-LINK,PE-LINK

PIOLine PLCInterface

1msec1msec1msecCycle Time(2Loop FBK)

MELSEC-Q(Mitsubishi Electric)

32bit Microcomputer16bit MicrocomputerProcessing CPU

MELSEC-Q(Mitsubishi Electric)

HDC-500ICS-2500（Fuji Electric）

MELSEC-A(Mitsubishi Electric)

Main CPU

MHPC-MMPC-32A（Sales end）

MPC-16A（Sales end）

Item

Power Supply Unit

Main CPU（MELSEC-Q）

Processing CPU（MELSEC-Q）

Position Sensor AMP

Servo Valve AMP

Breaker Unit

4. System Configuration（Hydraulic Cylinder Control System）

Load Cell

Valve Stand

Servo Valve

Control Panel

WR

BUR

WR

BUR

Position Sensor

CylinderPosition sensorAMP

TouchPanel

Relay

Servo

ＡＭＰ

ServoREF

< MainCPU >

・Sequence・Error detection

(MELSEC-Q)

<Processing CPU>

・APC

(MELSEC-Q)

Load Cell

Panel

Line PLC

Printer

ProgramLoader

DataGathering

・AFC

５．Display of Operation unit (Touch Panel)

① Status Display

② Test Mode Display

③Analog Monitor

④ Error History

6. The example of controller configuration by MHPC-M

Absocoder(64PLS/Rotation)

BUR Diameter：1450～1655mm

Line Speed ：1680mpmHeat and high humidityCooling-water scattering

1) The phase delay of a servo system is rectified on real time, and the line speed change under rolling is also followed at high speed.

2) The value change by heat modification etc. is also followed on real time.

3) It is only PLG which is installed in the local side, and an equipment addition is also easy.

If eccentricity is in Roll, change of rolling force will occur according to roll rotation, and it will become change of strip thickness. This equipment samples the load change according to a rotation angle with the PLG attached to BUR, and outputs the amount of roll eccentric compensation to the hydraulic cylinder controller.

RollEccentricityControl

Servo Motor×14Encorder×12Absocoder ×2Load Cell×4

WR Diameter：575～680mmLine Speed ：350～1600mpmHeat and high humidityCooling-water scattering

1) The angle of a grindstone is adjustedand the variation in grinding ability is prevented.

2) Force control of the whetstone according to roll speed is performed, and the amount of grinding is kept constant.

3) The grinding pattern - Complete grinding : Remove the surface roughness of Roll.

- Partial grinding: Remove the level difference by rolling.

It is equipment which forces on roll the grindstone installed in the rolling mill, makes it move in the direction of a roll axis, and grinds the roll surface. There is an effect of the improvement in the productivity by reduction of the number of roll exchange and the improved quality by roll surface roughness removal.

OnlineRollProfiler

Linear Sensor×4PT×8Laser Sensor×2Cylinder×4Servo Valve×4

Strip Temp ：400～600℃Strip Thick ：1.2～20.0mmStrip Width ：500～2180mmCoil Diameter：915～2600mmLine Speed ：max15m/sThere is mach steamCooling-water scattering

1) Accurate unit roll gap setting by

means of linear sensor

2) Advanced Q.O.C. (Quick Opening

Control) system

3) Accurate strip top end tracking

Small impact load at coiling first

period

In the equipment which rolls round strip, it is equipment which carries out quick opening of the roll at the time of strip top end passage, decreases a top mark, and raises product quality.

Down CoilerHydraulicCylinderController

Linear Sensor×2Load Cell×2Cylinder×2Servo valve×2

Strip Temp：400～1100℃Strip Thick：1.0～12.0mmStrip Width：900～1550mmLine Speed：max15m/sThere is mach steamCooling-water scattering

1) High-speed control with exclusive

application. (Sampling time:1ms)

2) A high precision and environment

proof position sensor is used.

3) There are various compensation

functions based on the past know-how.

- Mill modulus compensation

- Servo flow gain compensation

In order to strip to setting thickness with the roll of a rolling mill, it is equipment which operates the spool position of a servo valve and controls the position of a cylinder.

MillHydraulicCylinderController

System configurationSensorActuator

Line conditions etcFeaturePrincipleName

Load Cell

Panel

Pos. Sensor

AMP

Hyd. Cylinder

Pos. Sensor

Servo Valve

Load Cell

Line PLC

Mill

Hydraulic

Cylinder

Controller

(MHPC-M)

PT AMP

Pos. Sensor

AMP

Mandrel

Pos. Sensor

Servo ValvePT

QOC

Hydraulic

Controller

(MHPC-M)

Line PLC

Hyd. Cylinder

Laser Sensor

Grindstone

Motor Driver

Pos. SensorAMP

Grindstone

ORP

Controller

(MHPC-M)

Line PLCMill

Rotation angle

(MHPC-M)

Hyd. Cylinder

Pos. Sensor

Servo Valve

Load Cell

Hydraulic Cylinder Controller

TOP BUR

rotation angle

BTM BUR

Roll EccentricityController

CCD Camera×1Halogen Light×1PLG×1Laser Sensor ×3

Coil Dia：1200～2100mm

Coil Width：600～1350mm

Coil Rotation Speed：330mm/sec

1)Accuracy (Fish tail position accuracy: ±50mm)

Exclusive H/W and Algorithm have realized.

2) It is non-contact type equipment using CCD camera,

and stable detection can be performed.

3) With various image-processing technology, the

character on Coil, rust, Oil, etc. carry out disturbance

removal.

It is equipment which glares lighting from the lower part of Coil which rotates on Cradle, catches the shadow generated in a part for a tail end in CCD Camera, and detects a Coil fish tailposition. It aims at automation of entryside of process line.

CoilFish TailDetector

CCD Camera×4Purge Air：

2Nm3/minCooling water：40l/min

Strip Temp：400～1100℃Strip Thick：1.0～12.0mmStrip Width：900～1550mmLine Speed：max1680mpmThere is mach steamCooling-water scattering

Camera Position：Path Line＋700～800mm

1) Accuracy : Within±1.0mm

Accuracy is improved by triangulation, automatic

correction of camera position etc.

2) Cycle time：Less than ５.0ｍｓ

High speed operation processing using CPU

(Peintium M).

3) Environment-proof：

Eliminating influence of steam, water drops, etc. using

high performance purge device. Easy maintenance

because of no back light.

It is equipment which installs a CCD camera on the side guide between stands, detects the edge of strip, and calculates the strip center position and width.A signal is used for strip threading stability and strip tail pinching prevention and strip width control.

StripCenterPositionDetector

Eddy Current×8Electromagnet ×28

Strip Thick：0.3～3.2mmStrip Width：610～1610mmLine Speed：150mpmAL Coating Temp：660℃

1) Force of magnet : 10.5kgf/p’ce2) Amplitude of vibration: < 30% (Freq 0-10Hz)3) Correction of strip shape:

10mm p-p -> 2mm p-p (0.8mm t)4)Adjustment of pass line: 5-10mm

Strip Stabilizer system using electromagnet can correct a strip wrap, adjust a pass line position and reduce a strip vibrationFlat strip shape at air knife leads to:-Uniform coating-Less consumption of molten zinc

StripStabilizer

System configurationSensorActuator

Line conditions etcFeaturePrincipleName

Electromagnet

Pos. SensorAMP

Servo Driver

Pos Sensor

Coating Pot

StripStabilizerController(MHPC-M)

Line

PLCElectromagnet

Camera AMP

BOXCCD Camera

Strip

StripCenter Pos.

Detector(MHPC-M)

上位 PLC

Side Guide

Coil

CCD Camera

Cradle Roll

CoilFish TailDetector

(MHPC-M)

Line

PLC

Light

PLG Pulse

＜Sample of data gathering display＞

7. Adjustment support equipment （OPTION）As peripheral equipment of controller, we offer following equipment as option.(1) Data gathering equipment

This system consists of the notebook PC for the data gathering and indication, HDD for storing data and printers for printing a graph.This system receives data a constant cycle from a controller.Moreover, there are functions, such as a graph display and an output to CSV file.

Data Gathering PCHDD Printer

USB USB

For storing data For printing dataEthernet

Controller Controller

(２) Response measuring equipment

Freq. Response

This system has two types of analysis functions (step response test & frequency response test) to analyze the response of hydraulic cylinders.Especially automatic analyze function will save your labor. Measuring result of this function can be revised by the mouse-driven interface.Besides, 2 cylinders are analyzable at the same time. It increases your operating efficiency.

Isolation Module

Printer

Control System

Note PC

I/O Card

Analog OutputAnalog Input Step Response

Reference Signal×1，Cylinder Position Feed Back （or Force Feed Back）×2，Valve Travel×2

sampling period: 10kHz （0.1ms）Step Response Test

Reference Signal×1，Cylinder Position Feed Back×2 （2 axis simultaneous measuring executable）

measuring range: 0.1～50.0Hz （40Step / Decade）

Frequency Response Test

Measuring Signals Spec Function Name

Specifications

8. After service information of controllerController (MPC-16A, MPC-32A) is already a manufacture stop, and new spare-parts supply is

in the situation where it cannot respond.The after service information on each part is shown below.

MP-SCALE UNIT Panel(An attached catalog is referred to for details.)

After service expirationMHIEach BoardInductosyn Panel

Repair is possible (a term is based on a maker plan).

TOSHIBASONY

CCD Camera

After service expirationMHIImage UnitIP-1

After service expirationNECMonitor PC(FC-9801)

A repair is possible.(It may be unfixable with afailure situation.)

MHCPU BoardI/O Board

After service expirationFuji Electric

Program LoaderFM-R

MHPC-MA repair is possible.(It may be unfixable with afailure situation.)

Fuji Electric

HDC500ICS2500

MPC-32A

After service expirationNECMonitor PC(FC-9801)

After service expirationMHCPU BoardI/O Board

MHPC-MRepair is possible (a term is based on a maker plan).

Mitsubishi Electric

MELSEC-AMPC-16A

Updating recommendation

After Service MakerPartsController

Notes : This after service information is in the situation as of October, 2009.It may be changed by restrictions of the manufacture situation of parts, or quantity of inventory from now on.

Replace

Reuse

9. Replacement proposal of existing controller

We propose the optimal replacement for every existing system.The example of a replacement proposal of a rolling mill hydraulic controller is shown below.

＜ Existing controller ＞

＜ Replacement proposal of controller ＞

We also propose the replacement of sensor and actuator.

<Contents of replacement>1) Removal of an existing control panel2) Installation of a new control panel3) Wiring work (wiring about a new control panel )4) H/W and S/W remodeling of line PLC( if necessary)5) The test after replacement, and online adjustment etc

<Restrictions at the time of updating>1) Monitor PC is replaced and set to GOT for MELSEC, and is installed in the front of

control panel.2) By restrictions of H/W of a new control panel, H/W and S/W by the side of line PLC

may need partial to be changed.

Hydraulic Cylinder control Panel

Monitor PC

FC9801

Load Cell PanelProcessing

CPU

(M32－CPU386)

Main CPU

(HDC500)

Position Sensor AMP

MP-SCALEUNIT

Servo AMP Panel

MP-SCALEPre-AMP BOX

Relay Panel Valve Stand

Line PLC

MILL

ProgramLoaderFM-R

New Hydraulic Cylinder control Panel

Touch Panel

GOT

Load Cell PanelControl

CPU

(MELSEC-Q)

Main CPU

(MELSEC-Q)Servo AMP

Panel

MP-SCALE

Pre-AMP BOX

Valve Stand

Line PLC

MILL

Program LoaderWindows PC

Relay

Position Sensor AMP

MP-SCALEUNIT