Roll Grinder Modernization

Hybrid GrindControl 3D™

RollResearch provides 3D-grinder retrofits as turn-key projects.

Case Metso Service Point Borlänge, Sweden (see picture above):

• Modernization and relocation of two grinding machines.
• Grinding machine #1: Waldrich Siegen WS III T 50x12.000 (manufactured 1966).
• Grinding machine #2: Waldrich Siegen WST 60x12.000 (manufactured 1968).
• The project scope was equal for both grinders.

• The original machine foundation layout was modified for even the largest Kvarnsveden PM12 rolls (max. barrel length 11,6 m, max. diameter 2000 mm, max. weight 120 tons).
• Design of foundation pit and inertia block.
• Delivery and installation of spring damper units.

• Hybrid WRMD4-3D-CP-2000 four-point roll measuring device with Windows XP operator interface. (rollResearch has several different measuring devices designed for all types of grinders.)

• Complete electrical and automation rebuild:
  • New operator interface
  • New electrical cabinets
  • Siemens 840Di CNC for 3D Grinding™. ,
  • Simatic S7-300 PLC and wiring installations
  • Simodrive 611 drives.
  • Siemens 1FT6 axis servos
  • Siemens 1PH7 spindle motors. Possibility to use existing AC spindle motors and drives.
  • New cables and cable chains
  • New absolute linear encoders to all servo axes.

• Mechanical modernization and reconditioning:
  • Dismantling of grinder from their original locations
  • Painting of all parts
  • Relocation to new foundation onto new wedge blocks
  • Reconditioning of carriage bed: rescraping and alignment
  • Reconditioning and modernization of carriage:
    • Rescraping of gliding surfaces of X- and Z-guideways
    • Replacement of the old Z-gearbox with a new planetary gearbox
    • New X-axis ball screw and a planetary gearbox
    • New spindle and axis lubrication systems
    • New spindle axis and glide bearings
    • Precision machining unit for U-axis (crowning axis)
    • Integrated belt grinder (for wet and dry belt grinding)
    • New fences and platform.
  • Overhauling of headstock, new V-belts, bearings and lubrication system
  • Reconditioning of telescopic covers
  • Modernization of old roll steadies for automatic alignment
  • New roll steadies for rolls with large bearing housings
  • New dressing station incl. a rotating steel disc for diamond coated grinding wheels
  • Adapter plates between steadies and roll bearing housings.

  • Extension of workpiece bed.

• Other items in the delivery scope:
  • Grinding coolant cleaning system. Double system, one for each grinder.
  • Automatic wheel balancing system
  • S-drive unit
  • Floor plates around the foundation pit
  • Internet-based roll data administration program.

• 3D layout design and machine design with ProEngineer 3D CAD.
• Part production and assembly.
• Project coordination, erection, commissioning, operator training.
• Documentation.
• Internet teleservice.
• Service program and spare parts.