Straightening plants meeting high demands

Benefits at a glance

n Optimized straightening resultsn High productivity and reliabilityn Higher product quality and better residual

stress behaviorn Wide product range

n Long service life and minimized wear through long-life components

n Higher flexibility and availability due to automated quick roller change

Roller Straightening MachinesA new standard for straightening of Long Products.

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SMS group is one of the leading global system sup-pliers along the entire metallurgical value chain of our customers. The plants and machines manufactured by the SMS group fulfill the production requirements of a wide and demanding product spectrum. Modern section mills have to produce a wide variety of shapes and sizes as these are the demands of today’s market of structural sections and rails. Of critical importance is maintaining a high utilization factor in the mills by minimizing un-scheduled and scheduled stoppages. Of the latter, it is paramount importance reducing size changing times.

The latest technology for roller straightening machines is the CRS Compact Roller Straightener. The CRS de-signs are employed in medium and heavy section mills and represent the following technology:

n Higher product quality and better residual stress behavior

n Symmetrical application of the straightening force with the rollers supported on both sides

n Automatic straightening roller changing within 20 minutes

n Fixed straightening roller pitch for a large product range

n Automated straightening roller changing with less personnel

The straightening rollers of sandwich design are supported by bearings on both sides. All nine straight-ening rollers are individually driven, while the hydraulic cylinders allow the rollers to be adjusted under load.The CRS roller straightening machine is characterized by the following features:

n Overload protectionn Backlash-free mounting of straightening rollersn Maximum concentricity of straightening rollersn Automated setting of all adjustments mechanisms and

drives according to the straightening data set-upn Position transducers for reproducible recording of

all setting values

The design features of CRS roller straightening machines are as follows:

n Symmetrical application of straightening forcen Hydraulic axial position of each straightening shaftn Compensation of spring by hydraulic adjustment

mechanismsn Automated straightening roller changing with 20

minutes by changing platform on floor (double side/ single side) or by changings manipulator due to bay requirement

n Adjustable last straightening roll (roll no. 9) for opti-mized straightening results

Operator pulpit for CRS roller straightening machine

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Roller Straightening Machines Type CRS 2000-9H

Workshop assembly of CRS roller straightening machine at SMS group workshop in Mönchengladbach

Types and sizes of CRS roller straightening machines

The SMS group offers different sizes which are optimized for any demand. The CRS will be used to straighten sections i.e. H-Beams, I-Beams, Channels,

Rails, Equal or Unequal angles, Sheet Piles, U and Z, Universal flats and special sections. Below is an over-view of the actually types/sizes.

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The CRS roller straightening machines are equipped with one main drive for every straightening shaft. Every shaft is axially adjustable by one hydraulic cylinder to optimize the alignment of the straightening discs. The motor power will be customized according to the straightening program and the required produc-tivity. A straightening speed up 8 m/sec is possible.

The machine is equipped with a protection against scale for a long service life and reduced maintenance requirements. The scale may be disposed via convey-or belt or suction device.

A special feature of the CRS roller straightening machine is the adjustable bottom roll no. 9. This roll is equipped with an eccentric system for an adjustment range of ± 25 mm. This feature allows the influence of the up or down sweep without the re-adjustment of all other straightening rolls.

CRS roller straightening machine special feature adjustable bottom roll no. 9

Vertical max. section Product range Type straightening modulus up to force CRS 1400 1,850 kN 450 cm3 Web height: max 550 mm Flange width: max. 300 mm

CRS 1600 1,850 kN 570 cm3 Web height: max 600 mm (CRS 1600 S) (2,800 kN) (900 cm3) Flange width: max. 300 mm (Web/Flange: max. 750/300 mm)

CRS 1800 2,800 kN 900 cm3 Web height: max 750 mm Rails Rails 509 cm3 Flange width: max. 300 By max. tensile strength of 1,100 N/cm2

CRS 2000 5,000 kN 1,930 cm3 Web height: max. 1,000 mm Flange width: max 400 mm

CRS 2800 7,000 kN 2,800 cm3 Web height: max. 1,250 mm Flange width: max 500 mm* Based on yield point of 420 N/mm2

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Automatic quick change concepts

The roll change of the CRS roller straightening ma-chine will be executed automatically within 20 min. The changing concept for CRS roller straightening machines can be customized according to customer or building requirements. The changing platform for the straightening discs can be arranged on both entry and exit side (double side changing platform) or on either

side (single side changing platform) of the straigh-tening machine. If the installation space for a changing platform is restricted, a changing manipulator can be installed above the straightening machine. One example for a changing procedure with a double side changing platform is shown in the following picture.

Front view CRS roller straightening machines with entry and exit guide rollers

Automatic changing of straightening rollers by changing platform (double side)

Adjustable roll no. 9

Entry guide (with horizontal and vertical rolls and entry guide)

1. Shifting of operator side housing together with the used straightening rollers

2. Side shift of 1st changing car to take-over the used straightening rollers

3. Side shift of 2nd changing car with new straightening rollers into the straightener

4. Shifting of operator side housing back with new straightening rollers in operating position

Straightening plant for rails

The SMS group offers our customers rail straightening plants consisting of horizontal and vertical straighte-ners to process the highest quality rails, eliminating waviness and achieving straightness in full accordance with relevant international rail standards,. The stra-ightening machines are applicable to fulfill the latest high speed rail standards for the latest generation of high speed trains. High-speed railway lines in Germa-ny, Spain, Italy, France, Korea, Japan and China are laid with rails straightened almost exclusively on rail straighteners from the SMS group.

The straightening plant consists of one horizontal CRS roller straightening machine and vertical cantilever straightener. The machines are characterized by a very rigid, robust design with one individual main drive for each straightening shaft. An offline setup-model, in combination with a special tension control between the straightening rollers, enables optimum residual stress levels to be achieved in the product to ensure maximum service life of the rails on track.

Additionally to the special features of the CRS roller straightening machine is the rail straightening plant by SMS group which exhibits the following features.

n High housing rigidityn Blacklash-free mounting of rollers and sleeves on

the straightening shaft with a special design of the mounting sleeves

n Single drive system for each straightening shaftn Individual adjustable last roll of horizontal and verti-

cal straightener

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Vertical Straightener in operationRails straight as an arrow ensure safe running of high-speed trains worldwide

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Horizontal CRS Straightener Type CRS 1800-9HS & Vertical Straightener Type VRM 1300/1200/1100-7+1 Machine

Off-line setup model

The setup model calculates off-line the adjustment po-sition of the straightening rollers in vertical directions. After inputting the technological boundary conditions, physical parameters and the geometry of the product, the required adjustment positions of the straightening rollers will be determined in relation to the straight-ness and the remaining residual stresses of the profile type and size.

The results of the SMS group off-line setup model are:

n Offline calculation for all sections and rails in order to get preset values for roller adjustment

n Optimization of roller adjustment with respect to straightness and minimized residual stresses

n Output of geometric and mechanical values n Process data analysis and re-calculation of settings

Off-line roller straightener setup model – visualization screenshots

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Conventional Roller Straightening Machines

Conventional roller straightening machines find application in Medium and Light Section Mills. These cantilever type straightening machines, with a fixed or adjustable roller pitch, are designed for a wide product range.

The conventional SMS group roller straightening machines are characterized by the following design features:

n Compact and rigid machine housingn Axial position of all straightening shaftsn Simple elimination of scale due to smooth housing

frontsn Traction of rollers by bayonet ring and high- pres-

sure hydraulic clamping nutn Data management to preset machine settingsn Single drive for each straightening shaftsn Machine is available with height adjustment and or

shiftable as optionHorizontal Straightener Type HRM1400/1250/1100 – 8M

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Horizontal Straightener Type HRM1600 – 8+1MRAIL

Horizontal Straightener Type HRM1400-750 – 9M

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References

SMS group has a long and versatile experience for planning and execution such roller straightening machines for all different kind of applications. The experience is based on numerous machines delivered by the predeces-sor companies Schloemann, Siemag, Demag, Meer, Krupp, Möller & Neu-mann and Sack. With our continuous further development and the numer-ous roller straightening machines supplied, we have the major influence on the modern design and technology of straightening machines.

More than 450 roller straightening machines have been delivered by the SMS group worldwide to all leading rolling mills in Europe, North America, South America, Africa, Australia and Asia.

For more details please refer to our separate reference list for roller straightening machines.

STRONG MARKET POSITION . CUSTOMER FOCUS . DECENTRALIZED RESPONSIBILITIES . CORPORATE CULTURE

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SMS Meer GmbH

SMS group GmbH

Concast AG

Demag AG

DahlbrucherEisengießerei

Gebrüder Klein

Carl Eberhard WeissSchmiedebetrieb

MechanischeWerkstätten Harkort

DeutscheMaschinenfabrik AG

Siemag SiegenerMaschinenbau AG

Schloemann AG

Schloemann GmbH

Siegener Maschinenbau AG

Eduard Schloemann OHG

Schloemann-SiemagAktiengesellschaft

Mannesmann DemagHüttentechnik Meer

SMS Demag AG

SMS Demag AG

Mannesmann Demag AG

Paul WURTH S.A.

Paul WURTH S.A.SMS group

S.A. Anciens Etablissements Paul Wurth

Paul Wurth KGaA

Eugène Müller Kesselfabrek

SMS Siemag AG

elexis AG

elexis AGSMS group

elexis Elektro-holding GmbH

MaschinenfabrikMEER Aktien-gesellschaft

Gebr. MeerMaschinenfabriku. Eisengießerei

SMS Schloemann-Siemag AG

HISTORY

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The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these charac-teristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.

SMS group GmbHBusiness Unit Long Products Product Unit Heavy Section & Billet Mills

Ohlerkirchweg 6641069 MönchengladbachDeutschland

Phone: +49 2161 350-1739Fax: +49 2161 350-1754sectionandbilletmills@sms-group.comwww.sms-group.com

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