Solutions for the Metals Industry A4 - Tmeic.com

Why Our Systems Set Production RecordsThe advanced features of the TMEIC automationsystem allow operation of the mill at a higher rate,often setting production records. In addition, weproduce higher quality product, based on the superiorcontrol features and physical models developed byour experienced metals engineering team. The mainfactors providing this superior mill performance areoutlined below.System Features and BenefitsSuperior Control Features Result in Higher ThroughputThe metals engineering team has developed advanced control schemes for mill operationsresulting in higher mill speeds and the setting of production records.Q rad Q convAccurate Physical Models Result in a Higher Quality ProductAccurate level 2 models based on the physical processes in the rolling operation, use advancedtechniques such as finite element analysis. Models cover heat transfer, plastic deformation, millforce, and mill setup, resulting in improved control and higher quality product.The Engineering Team is World ClassThe metals engineering team has many years of mill experience and has built this extensiveknow-how into the automation system and the system engineering process.The Commissioning Engineers Know the Metals IndustryThe commissioning engineers have years of experience in the mills and are familiar with the millmachinery and the variable speed drive systems used in automation.Micro-Tracking Allows Higher SpeedsData on the micro-tracking list is gathered and tracked at a periodic interval of approximately 25mm, or a fixed time, resulting in better control accuracy and improved product quality.Simple, Scalable, Open Architecture Brings Lower Cost of OwnershipThe open control architecture uses standard controllers, computers, software, and communicationinterfaces, allowing easy expansion with additional commercially available hardware andsoftware, resulting in a lower system life-time costs.S S S Fewer Sensors Reduce CostsUsing advanced control features, the system requires fewer sensors, resulting in lower initialcost and life-time maintenance cost, with an increase in ROI.+X_Unified Engineering Tools Simplify MaintenanceUnified engineering tools for configuring and tuning drives and controllers result in fastercommissioning and simplified maintenance.Robust System Diagnostics Increases AvailabilityIn-depth system diagnostics built into the engineering tools, along with the option to use remotediagnostic services, increase system availability.© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 3 of 40

Total Solutions for Mill AutomationHot Mills Page 7Advanced Control Features Section Page• Shape setup• Object orientedsoftware design andprogramming• Highly integrated level1 & 2• Automatic gage control• Eccentricity control• Automatic profile &flatness control• Flying gage change(FGC)• Slab sizing press setup• Dual mode rolling setup(austenitic and ferritic)• Dual mill mode setup(Semi-continuous & batchoperation)• Lubricated rolling• Material propertiesprediction• Ultra-light gage modeling• Thermo-mechanicalrolling• Plate pattern optimization• Dual phase/Interruptedcooling• Piece sample tracking• Fast FM thread• Multi-mode coilingcontrolCaster & FurnaceControl .......................7Slab Sizing Press &Roughing Mill ............8Edge & Bar InductionHeaters ......................9Finishing Mill ........... 10Coiling TemperatureControl ..................... 11Coiler Control ..........12Steckel Mill ..............13Flying Gage Change 14Material PropertiesPrediction System ...15Cold Mills Page 16Advanced Control Features Section Page• Cold mill setup• Shape setup• Object-oriented level 2 design and programming• Highly integrated level 1 and 2• Automatic gage control• Eccentricity control• Automatic profile and flatness control• Flying gage change (FGC)• Differential tension controlFast & EffectiveLevel 1 Controls ......16Integrating Modelsfor Superior Control 17Process Lines Page 18Advanced Control Features Section Page• Product tracking• Weld/seam tracking• Heated/tail tracking for entry/exit automation• Minimum tension control• Maximum tension control• Optimized bridle load distribution• Elongation control (leveler & skin pass mills)• Loss compensation• Position control• Line setup• Setpoint distribution• Data acquisition• Open loop feed-forward tension controlTMEIC’s Approach toProcess LineAutomation .............18Designing the StripTransport ControlSystem ..................... 19Implementing the OpenLoop Feed-ForwardControl ..................... 19Page 4 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Total Solutions for Mill AutomationLong Products Page 20Advanced Control Features Section Page• Product tracking• Mill pacing• Flexible rolling & coolingschedules• Roll & bearingmanagement• Minimum tension control• Accurate shear control• Cascade speed controlRod Mills:• Sizing block control• Precision laying headcontrol• No Twist Mill controlSection Mills:• Saw managementsystemsRod Mills ..................20Section Mills ............21Product Tracking &Machine Monitoring 21Modernization Page 225DCS networkTM-DC DigitalinterfaceFront End (DFE)Innovation ControllerHMIDMC or Series Six4Master ControllerI/O6CPL or Series Six I/O BusSiltron SiltronSiltronHardwiredoperatordevicesTouchMMMScreen123TM-DC ModuleAssemblyTM-SeriesAC DriveAdvanced Control System Upgrades Section PageTMEIC’s control system is a scalable, open architecturereadily allowing future expansion and modernization.Legacy mill control systems are easily upgraded to thelatest hardware and software.1970’s LegacySystem .....................22Early 1980’sLegacy System ........23Late 1980’sLegacy System ........24Early 1990’sLegacy System ........25Non-TMEIC System 26Services Page 27World Class Mill Automation Section Page• World-class process and automation specialists forthe metal rolling and metal strip processing industries• Years of experience• Broad process knowledge• Project management skills.• Engineering team is supported by world-classcommissioning and field service personnel.Engineering Team ...27Technical Proposal ..28Design andProcurement ............29Factory SystemTest 30SystemCommissioning, .....32Training & Documentation32Maintenance &Service .....................33Products Page 35Products Section PageThe family of drives covers the power and supply voltagerequirements for new and legacy systems.Panel-mounted touch stations, pulpit HMIs, and level 1and 2 system software provide for all operator and controlneeds.AC/DC SystemDrives .......................35Operator Interfaces .36Software Toolsand Utilities .............37Mill Level 2 andModels .....................39© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 5 of 40

Hot MillsTMEIC has many firsts in hot mill automation, including the first use of all AC main drives, the first computer-basedhot mill setup, and the first and only implementation of semi-continuous rolling in a hot mill. Our Team has installedover 140 major beam, plate, and hot mill systems worldwide. This section discusses TMEIC’s advanced hot mill controlsystem.Caster & Furnace ControlCaster control includes precise mold level control and close drive coordination for varioustypes of casting machines. Several furnace control functions are closely coordinated tomaximize production, and minimize fuel consumption and the formation of scale on the slab.Slab Sizing Press & Roughing MillThe slab sizing press tailors the width of each slab, and the roughing mills reduce the thicknessto the particular order, based on inputs from the roughing mill models.Edge & Bar Induction HeatersThe edge heater and the bar heater produce a uniform temperature across and along the barbefore it enters the finishing mill.Finishing MillThe bar’s identity, temperature, thickness, and width are sent via the finish mill trackingfunction to setup models, which calculate a set of references for the control functions.Coiling Temperature ControlTo produce required mechanical properties, such as tensile strength and elongation, the rateof cooling and final temperature of the strip as it enters the coilers is precisely controlled.Coiler ControlThe coiler setup feeds references to the master controller, which then distributes them to theappropriate coiler controller for application.Steckel MillControls for the Steckel coiling furnaces and rolling mill are coordinated and optimized for allpasses.Flying Gage ChangePrecise mill control allows for different product to be made continuously from one long slab.Material Properties Prediction SystemThe computerized system improves the microstructure prediction accuracy of hot rolled steel.Page 6 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Caster & Furnace ControlCaster ControlFurnace ControlCaster Operator’s Overview ScreenTMEIC’s automation and control ofthe entire hot mill starts with thebusiness computer download of themill schedule for the new ladle. Theindividual caster control functionsinclude:• Ladle handling• Tundish level control• Mold level control and moldcooling• Cooling spray water flowcontrol• Coordinated drive controlincluding anti-sag feature• Width control and shearcontrol• Strand trackingFor the contents of each ladle,complete product tracking begins,and a coordinated system ofreference distribution is carriedon to the finished coil. The datacollected and distributed includesthe chemical properties of the steel,the mechanical properties, and theproduct dimensions.The furnaces maintain a steady delivery of temperature-controlled slabs to the mill. The main automation objectivesare to maximize production, minimize fuel consumption, and reduce scale formation.TMEIC differentiates its furnacecontrol by integrating physicalmodels with the furnace controlfunctions. Product Data Information(PDI) comes from the businesscomputer over Ethernet.Mill Pacing FunctionLevel 2 mill pacing uses PDI dataand tracking data to calculate theoptimum extraction time. It is alsocoordinated with the reheatingfurnace control (in the figure thewhite furnace control blocks may beprovided by the furnace OEM).BUSINESSCOMPUTERSLAB PDI DATAMODELSMILL PACINGTRACKINGFURNACEMODELSROUGHING MILLSETUPFURNACEMODELSREHEATTEMPERATUREFEEDBACKRMTEMPERATURESFEEDBACKZONETEMPERATURESCONTROLCHARGE &EXTRACTBURNER CONTROLBURNERMANAGEMENTFURNACE CONTROLZONETEMPERATURESENSORSFURNACERoughing Mill SetupLevel 2 model provides roughingmill setup data and interfaces to thefurnace control.FEEDBACKPROCESSINGTIMESREHEATFURNACESENSORSROUGHINGMILLSlab TrackingLevel 2 mill tracking function is linkedto the mill tracking and pacing.SENSORSFINISHINGMILL© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 7 of 40

Slab Sizing Press & Roughing MillThe slab sizing press and roughing mill reduce thewidth and thickness of the slab in preparation forthe finishing mill. With a large width reduction, theslab sizing press tailors each slab to a particularorder. The roughing mill models provide the targetwidth reduction to the level 1 controller, which takeseach slab to this desired width through a series ofpress actions. The press is electrically driven by alarge medium voltage motor and drive. Hydraulicallydriven top and bottom hold down rolls preventbuckling of the slab. Width gauges at the press entryand at the roughing mill exit validate that the targetwidth is achieved. The entire process is monitored byoperators on HMI screens.Significant Improvements to Operation of the Slab Sizing Press & Roughing MillAdvanced features of the TMEIC system includeimproved caster efficiency, increased mill widthreduction capability, improved width uniformity,and improved control tolerances. Control featuresinclude micro-tracking (fast tracking) of slab positionand speed, performed for the position and pressureregulators.The advanced sizing press model calculations include:• Die gap calculations for the anvil control• Head, body and tail draft calculations for widthreduction• Hold down roll force calculations for buckleprevention• Preforming length calculations for the taperedsections• Table lift calculations to compensate for increasingslab height• Slab elongation ratio and travel time calculationsSlab Sizing PressRoughing MillThe roughing mills (RM) reduce the width and thickness of the bar. They can bereversing, continuous, or a combination of both.Roughing Mill ScreenSlab Tracking RM ModelsControl starts with the level 2 slab tracking function, directing the level 1sequencing and regulators based on which zone the slab is in. Hot metaldetectors and other sensors are used to define the zone transitions. Specific millreferences distributed from the tracking and set-up models include:• Horizontal roll positions, side guide positions, and RM speeds• Vertical roll positions and draft compensations for the RM edgers• Spray selection for each of the millsDynamic References for Roughing MillAfter leaving the sizing press, the slab travels through the universal roughingmill stands where the width is further controlled by the edger drafting. Prior toeach pass, the level 2 set-up model provides a new set of references to the mill.Reversing Mill ScreenLooperless Tension Control Between Close Coupled Tandem Roughing StandsClose coupled roughing stands further reduce the width and thickness preparingthe slab for the finishing mill stands. Low tension control is applied between theclose coupled stands including coupled edgers.Page 8 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Edge & Bar Induction HeatersInduction heating is a fast and efficient method of heating moving metal, and it has been applied to various metalprocessing lines. TMEIC has applied large capacity induction heaters to hot strip mills since 1984. They are used foredge heating and bar heating to obtain uniform temperature before the bar enters the finishing mill, and have beeninstalled on many new hot strip mills in recent years.Three types of induction heaters are available:Solenoid TypeThis type has a flat heating characteristic,used in hot strip mills for bar heating.Transverse TypeThis type has a partial heating characteristicand has been used for bar center heating.C-shape Transverse TypeThis type has high heating efficiency and isused for edge heating.Solenoid Type Bar Heater- Power level: up to 9,000 kW- Inductor frequency: 1,400 Hz- Temperature rise: 40°CC-Shape Transverse Type Edge Heater- Power level: up to 4,000 kW- Inductor frequency: 300 Hz- Temperature rise: 50°CTemperature [Deg.C]1120110010801060104010201000980960BAR TEMPERATURE CURVEBAR TEMPERATURE CURVE (Hot Bar 1730 mm - 40 mm T)0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18DistanceAverageCenter-CenterCenter-SurfaceEdge-CenterEdge SurfaceBar Heating TemperatureSimulationBefore the edge heaters,the temperature differentialbetween the bar edge and thecenter is about 50º C.After the bar heaters, thetemperature differential hasbeen reduced to about 10º C.EDGE EDGEHEATER HEATER1EDGEHEATER2BARHEATER1BARHEATER2SIDE GUIDECROP SHEAR© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 9 of 40

Finishing MillUsers require strip with close dimensional tolerances and exact metallurgical properties. TMEIC’s control systemuses models based on physical and material behavior to set up the level 1 controls for the desired strip width, gauge,shape, tension speed, and temperature.Mill Setup Model Includes:Strip Thickness ModelThe finish mill setup modelprovides inputs to the level 1 rollgap absolute gage control.Strip Width ModelModels for exit spread, edgingdraft, and width reference provideinputs to the RM setup and level 1automatic width control.Temperature & SpeedThe temperature setup model (notillustrated here) provides inputsto the cooling spray controls andthe main drive speed.Shape ModelThe shape setup model providesinputs to the level 1 automatic stripprofile control, the automatic stripflatness control, and roll shiftingusing either the ContinuouslyVariable Crown or Pair Crosssystems (not illustrated here).Dual Mode Mill Setup has acombined functionality of level2 models for finishing mills andslab setup calculations for one(batch mode) or more products(semi-continuous mode) in theslab.FM Strip Thickness (FM Models)OPERATORINPUTSDESIREDTHICKNESSMODELSHOLDINGTABLETRANSFERFM EXITVERNERFM Strip Width (RM Models)OPERATOR INPUTS: FINISH WIDTH OFFSET EDGER LOAD DISTRIBUTIONHARDNESS &DEFORMATIONFEEDBACKMASS FLOWTHICKNESSMODELSFINISH MILLTEMPERATURESETUPMODELSFINISH MILLTEMPERATURESETUPFEEDBACK FEEDBACK FEEDBACKMODELSEDGING DRAFTDISTRIBUTIONMODELSWIDTHREFERENCETEMPERATUREMODELSEXIT SPREADFEEDBACKEXIT SPREADFEEDBACKHEAD & BODYMONITORCONTROLROLL GAP &ABSOLUTEAGCCONTROLFASTADAPTIVETHREADFEEDBACKGAGEMETERTHICKNESSFEEDBACKEXIT VERNIERTemperature SetupSpeed SetupShape SetupSENSORSROLLFORCESENSORSROLL GAPSENSORSMILLSPEEDSENSORSTHICKNESSSENSORSEXITWIDTHFINISHING MILLQ radiationQ convectionCONTROLAUTOMATICWIDTHCONTROLFEEDBACKFEEDFORWARDSENSORSFORCEPROFILESENSORSWIDTHPROFILEQ radiation43210Q conductionQ conductionQ convectionSlap/Strip Heat Transfer Model for RM,FM, and Coiling Temperature ControlSetup ModelsUsing roughing mill exit data, models calculate references:• A roll gap position, speed, and roll bending reference for each stand• Tension and position references for each of the inter-stand loopers• Position references for the finishing stand side guides and roll shifting• X-Ray gauge thickness and alloy compensation values• A reference for the bar’s exit width, gauge, and temperature• Finish mill speed-up rate and limit• A set of automatic gauge control predicted forces and transfer functions• Inter-stand cooling spray patterns and flow references from the outputs ofthe temperature modelPage 10 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Coiling Temperature ControlSteel customers today demand that mills produce specific mechanical properties for their products, such as yieldstrength, tensile strength, and elongation. The coiling temperature control maintains the rate of cooling and the finaltemperature (the temperature-time profile) of the strip to obtain the desired metal properties as it enters the coilers.TMEIC’s Coiling Temperature Control (CTC) features:Physics-based ModelsThe model of the cooling process generates cooling water flow setpoints, which are sent to the level 1 control toproduce the desired temperature-time profile as the strip moves toward the coilers. A process model encompassesvarious coiling temperature control strategies.Metallurgical-basedModelsThe CTC model includesthe effects of the steelphase transformation foraccurate prediction of thetemperature-time profilerequired for the optimummechanical properties.MODELSSTRIP SPEEDPROFILESENSORSTRACKINGPIECE SAMPLEFEEDBACKIN-COILFEEDFORWARDMODELSCOILINGTEMPERATUREFEEDBACKIN-COILFEEDBACKFEEDBACKFEEDBACKSYSTEMPARAMETERSIN-COILFEEDFORWARDTRACKINGPIECE SAMPLEFEEDBACKIN-COILVERNIERFINISHINGSPEEDSENSORSFM EXITTEMP.INTERMEDIATECOOLING ZONES ENSORSBOTTOMPYROMODELSCOILINGTEMPERATURESENSORSBOTTOMPYROSENSORSCOILINGTEMP.MILL EXITEARLY COOLINGZONELATE COOLINGZONE - VERNIERCoiler Temperature Control SystemEarly Coiling Temperature Cooling ModelThe CTC model takes finishing mill exit speed andtemperature plus feedback from the intermediate zoneand calculates the level 1 cooling water flow setpointsfor the early cooling zone to achieve the desiredquench rate and intermediate temperature.Dual Phase/Interrupted CoolingThe combination of interrupted cooling and modelingof low target temperatures achieves specific steelstructures such as the bainitic and martensitic.Late Coiling Temperature Cooling ModelThis model takes the final and intermediatetemperatures and calculates the late (vernier) coolingflow setpoints. The coiling temperature controlmodel utilizes several techniques including feedback,feedforward, and vernier temperature control to meetthe process objectives.Details of the Coiling Temperature Control ModelThe rate of cooling, the intermediate, and final temperature,are tied to the desired mechanical properties, thus precisecooling control is critical. TMEIC’s Dual Phase Coolingmodel illustrated above is described here.EarlyCoolingDUAL PHASE COOLINGRadiationLateCooling© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 11 of 40

Coiler ControlCoiler technology has advancedover the last ten years bringingmany new features including:• Various coiler side guidesoperating and coiling modes• Various coiler pinch roll gapoperating and coiling modes• Various wrapper roll gapoperating and coiling modesTMEIC provides advanced level1 controls to support these newfeatures. This page describes howa typical new automatic coileroperates. The operator HMI screenshows real time data with animatedcoiler graphics.Coiler Operator ScreenCoiler MachineCoiler Control Functions Deliver Completely Automated OperationSetup References Sent From ModelsCoiler operation starts with the associated setupfunction feeding several references to the level 1 controlpreparing for a given coil. The coiler master referencecontrol function then distributes these references tothe appropriate coiler controller for application.Hydraulic Jump ControlInitially, the unit rolls are positioned to a pre-set gap.As the strip passes by the roll, it applies a pre-set force,bending it around the mandrel. To avoid marking thestrip, the rolls jump clear of the strip head as it passesunder each roll. This is commonly called automaticjump control. When the strip is tight around themandrel, the unit rolls are retracted.Tail-end Slow Down and SpottingThere is a strip position calculator and tail-end spottingfunction that calculates the position of the strip’s tailendas it progresses down the run-out tables andcomputes the slow-down point for the end of the coil.Telescoping ControlAnother function in modern coiler systems is thecoil presentation or telescopicity control. This isaccomplished with sophisticated multi-mode hydraulicregulators on the entry side guides and steplessmandrel expansion control.Completely Automated Coil DeliveryAt the output of the coiler control system, each of thecoils is automatically:• Banded• Weighed• Inspected by the shape meter• Marked for shipmentThe overhead crane then moves the finished coils tothe storage area.Page 12 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Steckel MillThe Steckel mill is a unique type of reversing rollingmill, which can roll very large slabs to produce highquality plate and strip. Furnaces on both sides of themill provide heated space to store the increased lengthof coiled material produced during strip rolling. Thesecoiling furnaces allow for additional heat retentionand thermal consistency in the rolled piece, which inturn produces improved uniformity throughout therolled product.Steckel Mill with Coiling Furnaceslocated on either sideOn right - Operator’s Screenshowing:- Alarms & Manual Controlbuttons- Steckel Mill graphic- Real-time data- Screen navigation buttons atthe bottomWorld Class Features of TMEIC’s Steckel Mill Control SystemTriple Adaptive ModelThe model contains three separate control setups forthe head, body, and tail of the slab.Wide Product RangeControls can handle rolling both plate and coilwith thicknesses from 1 mm to 70 mm, withcomplex sequences and auto recovery from manualintervention.Pass to Pass AdaptationAll critical material parameters are measured and thecontrol setup calculated for the next pass.Tapered Thickness RollingThe thickness is fully programmable so that the headand tail can be reduced to a different amount thanthe body. Uniform thickness is produced in the finalpass.Absolute Hydraulic Automatic Gage ControlThe AGC works to achieve constant target thicknessand/or follow a predetermined thickness trajectory.Temperature Controlled RollingThe metal temperature is controlled so the desiredmechanical properties can be achieved.Coiling Furnace Temperature ModelThe temperature model calculates the heat transfer tothe coil in the furnace.Finishing Temperature ControlThe model calculates the desired speed of each passbased on the target temperature in the coil body.Coiling Temperature ControlThe run out table sprays are controlled to produce thetemperature-time profile for the desired metallurgicalproperties.© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 13 of 40

Flying Gage ChangeThis page gives an overview of an advanced control technology applied to hot strip mills producing light and ultralightgage strip. These mills work with long slabs and produce many coils of various thicknesses from one slab. Flyinggage change (FGC) technology is used to change the strip thickness.The diagram shows three products A, B, and Ccontinuously rolled from one slab withoutde-threading strip from the stands. In the case of ahot mill, the mill cannot be slowed down to makechanges, so FGC is a highly coordinated controlprocedure involving multiple process actuators.The first semi-continuous hot mill FGC system,implemented by TMEIC, was in 2000.CoilA-1CutPointCoilA-2CutPointCoilA-3CutPointCoilB-1CutPointCoilC-1Product A Product B Product CThe level 2 models, which control and optimize this change, as well as the mill functions affected, are shown below.TFTCCasterShearTUNNEL FURNACETEMPERATURECONTROLTunnelFurnaceCropShearFSBEdgerRTWROLLTEMPERATUREAND WEARSSUSHAPESETUPDMMSDUAL MODEMILL SETUPFDTCFINISHING DELIVERYTEMPERATURECONTROLOptional CoilerF1 F2 F3 F4 F5 F6 F7HighROTSpraysCOILINGTEMPERATURECONTROLSpeedShearCTCRotaryCoilerROTSpraysCoilerTunnel FurnaceTemperature Set-pointsExtract TimeDescale Flows SetupStand Strip exit thicknessStand SpeedMill Spray FlowsLooper TensionRoll ForceLead SpeedDual Mode MillEdge draftHead & Tail AWC ref'sRoll profile actuator positionvs. bending transfer functionsScans scheduleRoll ShiftRoll BendingRunout TablesSpray ActionsTMEIC has implemented two types of FGC:Type 1. Constant Finishing Mill Exit SpeedWith this strategy, the mill speed is raised to thetarget level prior to the transition, then the gap andup-mill stand speeds are transitioned using a ramp.During the change, the looper, speed, gap, and profileadjustments are tracked and tightly controlled, andthe finishing mill exit speed is held constant.Type 2. Constant Finishing Mill Exit Strip Mass FlowWith this strategy, control of strip speed at the run-outtable and exit mass flow control are required. Thegap and stand speeds are progressively transitioneddown-mill using a ramp. The looper, speed, gap, andprofile adjustments are tracked and tightly controlled,and the finishing mill entry speed is held constant.Page 14 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Material Properties Prediction SystemMaking High-Strength Steels at Lower CostSteel researchers are continually developing high-strength rolled steels for applications such as automobile bodies.A way to predict the microstructure and mechanical properties of these steels would allow the production of finegrain size with high strength using lower grade metal. Only small quantities of additional alloying elements wouldbe required.An integrated system combining simulation of the hot rolling process withprediction of the microstructure of the hot rolled steel has been developedby TMEIC, enabling the development of new production processes for finegrain size steel. The system has been proven in predicting grain size.The two steel micrographs shown here illustrate coarse grain structure (lowstrength) and fine grain structure (high strength).Course GrainStructureFine GrainStructureThe Material Properties Prediction System has Two Main PartsRolling Process Modeling SystemThis system evaluates rolling force,torque, power, etc., using equationsmodeling the rolling process. Thecalculation uses numerical methods andis based on a specified distribution ofroll forces and temperatures among thestands.Rolled Steel Microstructure PredictionSystemThis system performs metallurgicalcalculations taking into account the rollingand subsequent cooling processes. Theprocess phenomena include static anddynamic recrystallization, grain growth,and the austenite-ferrite transformation.Typical Prediction ResultsFinisherLaminarCoolingTransition of austenitic graindiameter with deformation.Upper plot 850°, Lower 950°C.Transition of volume fractionin each structure withdeformation.Upper plot 850°, Lower 950°C.Temperature1050-grainCASE -B750 -grainCASE-A680880 Deformed- grainFerrite+pearlite structure720640Sub- grainsin- grain Fine ferrite+pearlite structureTimeEffect of Rolling & Cooling on Grain Structure© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 15 of 40

Cold MillsTMEIC has automated over 100 cold mills worldwide. This vast experience includes controls for tandem mills, singleand multi-stand reversing mills, temper mills, and Sendzimir mills. TMEIC’s automation system provides superiorcontrol based on accurate process models and tightly integrated level 1 control. Some examples are illustrated here.Tandem MillSingle Stand MillFast and Effective Level 1 ControlsCoordinationCoordinated in-coil adjustments use measured andcalculated values to maintain targets.Automatic Gage ControlAutomatic Gage Control (AGC) employs mass flowcalculation, feedforward, feedback, tension, and slipcompensation.EccentricityEccentricity control reduces the effect of backup rollirregularities on thickness using Fourier Series Analysis.Automatic Flatness ControlAdvanced data filtering, parabolic flatness control, tiltcontrol, segmented coolant spray control, and shapemaintenance.Flying Gage ChangeFast coordinated control changes minimize strip breaksand mass flow disturbances.Micro-trackingHigh-speed data acquisition and tracking allows fasterand more accurate control action.GageDeviation[um]50Last Last Stand stand Exit exit FGC taper length < 5m < 5m-5050EccentricityOutput[um]Switch EccentricityControlControloffoffThickness [um]-500 10 20 30TimeResults of Eccentricity Control Time (sec)Fast Flying Gage Change ControlPage 16 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Integrating Models for Superior ControlTMEIC’s automation system provides superior cold mill control based on accurate level 2 process models andintegrated level 1 controls. Some process models are listed below along with the shape control block diagram.Level 2 Process Models Ensure Production of Quality ProductForce and Power ModelsForce, torque, and powermodels with the effects oftension and friction.Flow Stress ModelsFlow stress models with thematerial chemistry and workhardening effects on elongation.Friction ModelsCompensation for coefficient offriction variations.Strain ModelIn-coil strain distribution.Roll Wear ModelThermal and wear effects onroll diameter profile.InteractionsInteractions betweentension, forward slip,friction, and speed.Textured RollsThe coefficient of frictioneffect of textured rolls.Product VariationsProduct dependent transferfunctions for level 1 control.DeformedRollRadiusEntryThicknessEntryTensionRollRadiusMetal Deformation ModelRollForceExitThicknessNRollForceDeformationPowerPressure due toroll-strip frictionPressure due tometal deformationresistanceExit TensionReferences from the model provide the setup forlevel 1 controls, as shown in the diagram below.ShapeControlBlockDiagramOperatorRB AdjustRoll Side-ShiftPositionModelCMSetupModelThread/RunFeedbackFlatnessFeedbackType of RollBending andShiftRoll ForceRollContourModelRollWearModelRollThermalModelGround Roll CrownStack Crown VerniersStripTensionRollDeflectModelModelStripBucklingModelStrip PropertiesProfileVernierPDI EntryProfileRoll profileactuatorBucklingThresholdModelRoll GapContourPhysicalModelModelStripPhysicalModelRollGapCrownStrip Recalculation for Limit ConstraintsPass #Max/Min Roll Gap CrownsStripStrainRangePassConstraintsStrip ConstraintsPass #Per Unit Profile andStrip ConstraintsNo TensionThreadRunModelStripFlatness&ThicknessStrategy1. Run Condition2. Mill Fully Threaded3. Post Entry ThreadFlatnessRoll SensorBending &ShiftingReferencesControlClosed LoopFlatnessControl© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 17 of 40

Process LinesIn recent years, changes in strip processing linemechanical configurations and increasing customerexpectations for strip quality and line productivityhave combined to create demands on the capabilitiesof electrical drive and control systems. TMEIC hasresponded with an approach that addresses theunique requirement of effective strip transport in stripprocessing line applications. The benefit to customersis a level of performance that can support high linespeeds and a broad range of products processed ona single line. In addition, TMEIC helps insure a levelof performance that eliminates strip breaks, bridleslippage, furnace necking, catenary scratching, andother performance problems that result in degradationof finished strip quality.TMEIC’s Approach to Process Line AutomationFor superior process line control, it must beunderstood that the main function of thecontrol system is to provide effective striptransport under all line operating conditions.To achieve this, TMEIC:• Analyzes the line control in terms of thepower required by the strip transportequipment, then models the line interms of power elements:a. Power source – positive motor torqueb. Power sink – negative motor torque• Applies an understanding of the powerrequirements for each strip transportmachine to create a control system basedon a feed forward tension referencingsystem that minimizes dependency onclosed loop regulator performance.ENTRY ACCUMULATORPAYOFFREELPINCH ROLL(THREAD ONLY)FLATTENER PRE-CLEANER#1 BRIDLERINSE#2 BRIDLE #3 BRIDLEKG/mm^2TENSION ZONE 1#1 BRIDLEENTRY TENSIONTENSION ZONE 2 TENSION ZONE 3#2 BRIDLEENTRY TENSION(ZONE 1 BASE)FLATTENERLOSSESCLEANINGLOSSESNORMALIZEDACCUMULATORTENSION(ZONE 2 BASE)#1 BRIDLEEXIT TENSION1/2 TOWERLOSSES1/2 TOWERLOSSES#2 BRIDLEEXIT TENSIONPROCESS TENSION(ZONE 3 BASE)PROCESSLOSSES#3 BRIDLEENTRY TENSIONCLEANINGLOSSES#3 BRIDLEEXIT TENSIONProcessing Line Tension ProfilePage 18 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

PAYOFF REELMOTOR POWER (KW)BRIDLE 1 ROLL 1MOTOR POWER (KW)BRIDLE 1 ROLL 2MOTOR POWER (KW)ACCUMULATORMOTOR POWER (KW)BRIDLE 2 ROLL 1MOTOR POWER (KW)BRIDLE 2 ROLL 2MOTOR POWER (KW)INERTIALOSSES (KW)+INERTIALOSSES (KW)INERTIA+ +LOSSES (KW)INERTIALOSSES (KW)+INERTIALOSSES (KW)+INERTIALOSSES (KW)+FRICTIONLOSSES (KW)FRICTION+LOSSES (KW)+FRICTIONLOSSES (KW)+FRICTIONLOSSES (KW)+FRICTIONLOSSES (KW)+FRICTIONLOSSES (KW)+ROLL 1 LOADCONSTANT (%)XROLL 1 LOADCONSTANT (%)XROLL 1 LOADCONSTANT (%)XROLL 2 LOADCONSTANT (%)XTENSIONPOWER (KW)TENSIONPOWER (KW)TENSIONPOWER (KW)TENSIONPOWER (KW)XLSCONSTXLSCONSTXLSCONSTXLSCONST–+ +–+ –+–ROLLS DOWNBRUSHES DOWNFLATTENERLOSSES (KG)PRECLEANERLOSSES (KG)0.5* TOWERLOSSES (KG)ZERO (KG)0.5 * TOWERLOSSES (KG)ZERO (KG)PAYOFFTENSION (KG)LS = LINE SPEED (METERS/MINUTE)ACCUMULATORTENSION (KG)LS = LINE SPEED (METERS/MINUTE)TANKTENSION (KG)Designing the Strip Transport Control SystemTMEIC executes three major steps in designing an effectivestrip transport control system:• Analyze the primary strip transport machines (reels,accumulators, and bridles) using off-line models todetermine the capacities and limitations of each.• Develop a tension profile one-line diagram to outlinethe requirements for tension reference distribution, losscompensation, tension limits, and regulator configuration.• Develop a run/jog matrix showing which drive and/ordrive groups are involved in each run or jog function, theregulator configurations for each mode, and the driveloading requirements.Implementing the Open Loop Feed-Forward ControlThe feed-forward network consists of on-line control algorithmsproviding:• Compensation for the inertia of the motors, gearboxes, anddirectly connected mechanical equipment.• Compensation for friction and windage losses of motors,gearboxes, and directly connected mechanical equipment.• Strip tension referencing to load the drives with thetorques determined from line tension setpoint data andprocess loss calculations.The complete system consists of closed loop regulators andopen loop feed-forward elements. However, the main elementis the feed-forward control which minimizes the need forreactive correction by the closed loop regulators. The result issuperior strip transport performance.ModelsOff-lineAlgorithmsOn-lineDrivesLine parametersStrip flattenersTension levelersTemper millsReduction millsSide trimmers/slittersStrip bendingCatenary tension/positionConfiguration ParametersControlTorqueBridle load distributionFriction & windage loss compensationInertia compensationStrip bending loss compensationStrip catenary/position controlSide trimmer/slitter loss compensationWeld trackingSetpoint distributionAutomation System Delivers Significant Customer BenefitsTMEIC’s advanced process line controls have been applied to metal processing lines with excellent results. Ourexperience includes controls for galvanizing lines, pickle lines, tinning lines, coating, and painting lines. Actualsystem operation and line performance data obtained from operating mills have demonstrated the followingcustomer benefits:• Reduced operator intervention• Zero product quality degradation• Maximized line throughput and uptime• Maximized product capacity• Seamless product transitions© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 19 of 40

Long ProductsRod MillsTMEIC has extensive experience automating rod millsworldwide. Our advanced rod mill control system providescustomers with many advantages including:Looperless Minimum Tension ControlLow tension is obtained using predictive control by measuringtorque and controlling stand speed, with upstream standsunder cascade control. Tension-free rolling is achievedbetween mill sections to assure safe rolling and closetolerance to bar geometry.Precision Laying Head ControlPrecision control and coordination of the pinch roll and layinghead combination provides the highest quality rings from millequipment.The Latest Drive TechnologyThe medium voltage TMdrive-70, employed for the no-twistblock, uses IEGTs in the converter and inverter. These providehigh reliability, low voltage gating losses, and high-speedswitching for fast drive response.A Fully Integrated Automation SystemThe architecture combines level 1 and 2 control and dataacquisition in one easily expandable system.Mill ExperienceIn-depth mill engineering experience and field servicecapability, is available worldwide.Rod MillsHigh Speed Rod and Bar TechnologyMorgan Construction Company, USAProduct Tracking and Machine Monitoring through the Rod MillThe automation system tracks billets from the furnace, through the rolling stands, cooling bed, no-twist block, andshears, to the finished coils. This product data is sent to the level 1 controls at each stage of the process. Real-timeprocess data is immediately available to the operators in the various sections of the mill. The HMI screen below isan example of an operator’s screen for a mill section showing the drive current, rod velocity, and reduction for eachstand, as well as navigation buttons to access other screens.Roughing StandsIntermediate StandsFinishing StandsRod SizingNo Twist BlockCooling BedLaying HeadTypical Operator’s Screen for Roughing Mill SectionTypical Rod Mill showing Product Flow and Operator StationsPage 20 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Section MillsTMEIC has automated many beam mills around the world using its advanced mill control system. This system providesmany advantages:Minimum Tension ControlLow tension is obtained using predictive control by measuring torque and controlling stand speed, with upstream standsunder cascade control. Tension-free rolling is achieved between mill sections to assure safe rolling and close shapetolerance.Precision Shear CuttingHigh-speed control of the shear blades and accurate timesynchronization to line speed provides exact beam lengths.Latest Drive TechnologyThe medium voltage TMdrive-30, employed for many mill applications,uses IGBTs in the PWM inverter, with high-speed switching for fastdrive response, and heat pipe cooling to provide high reliability.Fully Integrated Automation SystemThe universal control architecture combines level 1 and 2 control,product tracking, and data acquisition in one easily expandablesystem.ExperienceWorldwide mill engineering experience and field service capability areavailable wherever your mill is located.Diagram of H-Beam Finishing MillProduct Tracking and Machine Monitoring throughout the MillThe stored schedule from the mill computer contains thedesired beam size and length, initial setup for each stand,and the roll speeds. The automation system tracks billetsfrom the furnace, through the rolling stands and shears tothe cooling bed and stacks of finished beams. This productdata is sent to the level 1 controls at each stage of theprocess. Real-time process data is immediately availableto the operators in the various sections of the mill bymeans of the color graphic HMI screens.SCHEDULESETUP PERBEAM SIZECONTROLSPEEDTORQUECONTROLPRECISIONCUTTINGTRACKINGMILL WIDEPER ORDERCONTROLFINISHEDLENGTHShearsMill Stands`ColdSawCooling BedSimplified Beam Mill Control SchematicStackingOperator’s Mill Drives HMI Overview Screen© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 21 of 40

ModernizationWhen it’s time to modernize existing drives and control systems, TMEIC has the technology and project engineeringteam to assure a smooth migration path. The following pages chronicle the system architectures implemented and theopportunities for modernization.1970’s Legacy System Architecture561423Item Equipment Notes Benefits123456Drive Modernization- Modernize Siltrol drives with the TMdrive-DC orTM-Series AC drives. The DC modernization canoccur at one of three levels:• Digital Front End (DFE)• Panel with DFE• Complete drive replacement- Both the TMdrive-DC and TM-Series AC drives canbe controlled from I/O or one of several local areanetworks (ISBus, Profibus-DP, DeviceNet,TOSLINE-S20)- Configuration from the ToolboxMaster Control Modernization- Replace the electromechanical relay and TTL logicwith a new Controller & I/O- The VME rack allows a wide variety of third-partymodules to interface with virtually any industrialLANColor Touch Screen Operator Interface- Graphical touch screens for operator control of thedrives- Hardwired-like performance using a high-speedEthernet communications linkHuman Machine Interface (HMI)- Graphical overview of drive system status anddiagnostic information- Integral historian provides flight recorder-likefunctionality- More precise and consistent control with the digitalregulators- The local area network interface between thedrives and master control provides for an accuratespeed reference distribution to the drives- With the TM-Series AC and TMdrive-DC drivessharing common control hardware components,spare part costs are minimized in AC-DC hybridsystems- Digital solid state electronics are far more reliableand precise than electromechanical relay and TTLlogic- The open architecture of a VME rack provides aseamless interface with the rest of the controlsystem- Vast improvement in flexibility of the design,allowing the interface to evolve without impactinghardware- Diagnostic data for process operation and drivestatus- Intuitive interface for system status and diagnostictools- Historian provides powerful insight into processeventsPage 22 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Early 1980’s Legacy System ArchitectureController641523Item Equipment Notes Benefits123Drive Modernization- Modernize Siltron drives with the TMdrive-DC orTM-Series AC drives. The DC modernization canoccur at one of three levels:• Digital Front End (DFE)• Panel with DFE• Complete drive replacement- Both the TMdrive-DC and TM-Series AC drivescan be controlled from I/O or one of severallocal area networks (ISBus, Profibus-DP,DeviceNet, TOSLINE-S20)- Control can operate with a digital tachometer orwithout a tachometer- Configuration of the control from the Toolbox- Siltron drives transitioned to AC technologywill eliminate the periodic expense of DC motormaintenance- Drives modernized with TM-DC controls providemore precise control and improved diagnosticdata- With the TM-Series AC and TM-DC sharingcommon control hardware components, sparepart costs are minimized in AC-DC hybridsystems456Master Control Modernization- Replace the dated Series Six and/or DMC witha new Controller & associated I/O- The VME rack allows wide variety of third-partymodules to interface with virtually any industriallocal area network- Controller is programmed in function blocklanguage using the ToolboxColor Touch Screen Operator Interface- Graphical touch screens for operator control ofthe drives- Hardwired-like performance using a high-speedEthernet communications linkHuman Machine Interface (HMI)- Graphical overview of drive system status anddiagnostic information- Integral historian provides flight recorder-likefunctionality- Open architecture of VME rack provides aseamless interface with the rest of the existingcontrol system- The Toolbox provides a common application forboth the controller and all of TMEIC’s systemdrives- Vast improvement in flexibility of the design,allowing the interface to evolve withoutimpacting hardware- Diagnostic data for both process operation anddrive status- Intuitive interface for system status anddiagnostic tools- Historian provides powerful insight into processevents© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 23 of 40

Late 1980’s Legacy System ArchitectureHMIDCS networkinterfaceControllerTM-DC DFEDigital Front EndTM-DCModuleAssembly4DMC & Series SixMaster Controller6I/OCSF & C-Bus15HardwiredoperatordevicesDC300SiltronSilco2TM-SeriesAC DriveTouchScreenMMM3Item Equipment Notes Benefits123456Drive Modernization- Modernize DC300, Siltron, and SILCO driveswith the TMdrive-DC or TM-Series AC drives.The DC modernization can occur at one of threelevels:• Digital Front End (DFE)• Panel with DFE• Complete drive replacement- Both the TMdrive-DC and TM-Series AC drivescan be controlled from I/O or one of several localarea networks (ISBus, Profibus-DP, DeviceNet,TOSLINE-S20)- Control can operate with or without a digitaltachometer- Configuration of the control from the ToolboxMaster Control Modernization- Replace the dated Series Six or DMC with a newController and associated I/O- The VME rack allows wide variety of third-partymodules to interface with virtually any industriallocal area network- Controller is programmed in function blocklanguage using the ToolboxColor Touch Screen Operator Interface- Graphical touch screens for operator control ofthe drives- Hardwired-like performance using a high-speedEthernet communications linkHuman Machine Interface (HMI)- Graphical overview of drive system status anddiagnostic information- Integral historian provides flight recorder-likefunctionality- DC300, Siltron, and SILCO drives transitionedto AC technology will eliminate the periodicexpense of DC motor maintenance- Drives modernized with TMdrive-DC controlsprovide more precise control and improveddiagnostic data- With the TM-Series AC and TMdrive-DC drivessharing common control hardware components,spare part costs are minimized in AC-DC hybridsystems- Open architecture of VME rack provides aseamless interface with the rest of the existingcontrol system- The Toolbox provides a common application forboth the controller and all of TMEIC’s systemdrives- Vast improvement in flexibility of the design,allowing the interface to evolve withoutimpacting hardware- Diagnostic data for both process operation anddrive status- Intuitive interface for system status and diagnostictools- Historian provides powerful insight into processeventsPage 24 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Early 1990’s Legacy System ArchitectureController461523Item Equipment Notes Benefits12345Drive Modernization- Modernize your DC2000 drives with theTMdrive-DC or TM-Series AC drives. The DCmodernization can occur at one of three levels:• Digital Front End (DFE)• Panel with DFE• Complete drive replacement- Both the TMdrive-DC and TM-Series AC drivescan be controlled from one of several localarea networks (ISBus, Profibus-DP, DeviceNet,TOSLINE-S20)- Configuration of the control is from the ToolboxMaster Control Modernization- Replace the dated IOS or OC2000s with a newController and associated I/O- The VME rack allows wide variety of third partymodules to interface with virtually any industriallocal area network- Controller is programmed in function blocklanguage using the ToolboxColor Touch Screen Operator Interface- Graphical touch screens for operator control ofthe drives- Hardwired-like performance using a high-speedEthernet communications link- DC2000 drives transitioned to AC technologywill eliminate the periodic expense of DC motormaintenance- Drives modernized with TMdrive-DC controlsprovide more precise control and improveddiagnostic data- With the TM-Series AC and TMdrive-DC sharingcommon control hardware components, sparepart costs are minimized in AC-DC hybridsystems- Open architecture of VME rack provides aseamless interface with the rest of the existingcontrol system- The Toolbox provides a common applicationfor both the controller and all of TMEIC’s systemdrives- Vast improvement in flexibility of the design,allowing the interface to evolve withoutimpacting hardware- Diagnostic data for both process operation anddrive status6Human Machine Interface (HMI)- Graphical overview of drive system status anddiagnostic information- Integral historian provides flight recorder-likefunctionality- Intuitive interface for system status anddiagnostic tools- Historian provides powerful insight into processevents© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 25 of 40

Non-TMEIC System ArchitectureLevel 2ControlL2TouchScrTouchScr eeneen TouchScreenHMIViewerWorkStationControllerOtherControllersNew Control network3New EquipmentHMIBridgeControllerFiberOpticLinkFullControlNew I/OControllerFiberOpticLinkNo Control(SignalsMapping)New I/OControllerFiberOpticLink2DRVDRVDRVTMdrive®TMdriveTMdriveOld Equipment- System “S”PartialControlControllerNo Control(SignalsMapping)ControllerOld System NetworkFullControlController4Old I/ODRIVEA VOld I/ODRIVEDRIVEA VA VOld I/O1The modernization or replacement of an old controlsystem supplied by another vendor presents animplementation challenge. The replacement projecthas to minimize:• Additional shutdown periods• Post-switchover production disturbances• Installation complexity and costDue to incompatibility of old networks and components,the standard approach is to install a complete newsystem, remove the old one, and execute the switchoverin one big step.This requires an extended shutdown period andintroduces significant risks because all system levelsmust be started and tuned up at the same time. A wayof minimizing risk is to connect all the new I/O in parallelwith the existing I/O, but this is very costly due to theadditional engineering and installation materials andlabor.TMEIC’s approach to these problems uses connectivityto the old system components and a step-by-step controltakeover. The figure above shows an intermediate stagein an implementation.Approach to Replacement of System “S”Item1234Equipment NotesEstablish Controller Connectivity- Install interface boards in the old controllers; (these may be two types, for example MultiBus I and II)- Install matching interface boards in the new controllers (VME rack) and establish the data exchangeusing fast fiber optic links (with some other vendors’ systems, DECNET communication may be used fordata exchange)- Map the data to and from the old system to and from the new global control networkNew HMI System- The new HMIs and level 2 computers are easily implemented and are initially tested in passive mode,then switched to bidirectional data flow (with other vendors’ systems, the new level 2 computer acts asthe communication gateway, both for HMI and level 1 control)Drive Modernization- The new drives are installed and connected to the new controller. In the initial stage, the new controller onlyacts as a drive bridge since the old controller is still in active operation- In some cases the old drives temporarily run with the new controller. In this case, the old controller justbidirectionally maps all drive and I/O signals to the new controller (with other vendors’ systems, some of theold controllers and drives may be retained and kept active, and may communicate through the level 2 gatewayto the HMIs)- By switching over small sections of I/O and associated functionality during brief shutdowns, no productionstoppages or interruptions are introducedPage 26 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

ServicesTMEIC’s Metals Engineering Team in VirginiaDedicated Metals Engineering TeamThe metals engineering team is dedicated to the industry. Many of the metals engineers have over 30 years ofmill and control system experience. This background, combined with state-of-the-art technology, enables TMEIC toconsistently meet the demanding requirements of the metals industry.Our experienced mill application engineers jointly define the equipment and control strategy with our customer’sengineers. This is followed by detailed design of the operator stations, and configuration of the drives, the millmodels, and the controllers. The phases of the project engineering work are illustrated below. Success is guaranteedby close coordination between the factory team, the customer team, and the field engineering team as indicated bythe icons in the diagram.TechnicalProposalSpecificationCustomer TeamSystem FunctionalSpecification+ Customer ReviewDetailedSoftwareDesignFactoryAcceptanceTestSystemCommissioningSystemMaintenanceandServiceField TeamFactory TeamDetailedHardwareDesignSystemComponentProcurementTraining Team© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 27 of 40

Technical Proposal and Functional SpecificationDuring the planning stage of the project,experienced application engineers preparea technical proposal that includes:ONLINE DATAGATHERINGPRIMARY & SECONDARYLEVEL-2 COMPUTER • Customized system architecture foryour project• Detailed equipment specificationsINFORMATION LANCONTROL LAN• Formal bid documentationREMOTEI/OENTRYPLCREMOTEI/OCENTER 1PLCREMOTEI/OCENTER 2PLCREMOTEI/ODELIVERYPLCSpecificationsOur application engineers are highlyqualified for this proposal work, and manyof them have over 30 years of metalsindustry experience. In addition, theyare actively involved in industry technicalorganizations, in which they author papersand conduct training seminars at variousforums, for example:• IEEE – Institute of Electrical & ElectronicsEngineers• AIST – Association for Iron & SteelTechnology• China International Steel CongressAfter project approval, our application engineers prepare a systemfunctional specification that includes:• Customized system architecture with an electromechanical one-linediagram for your project• Detailed equipment specification:- Motors- Drives- Controllers- I/O devices and modules• Complete operational descriptionTo ensure we meet your requirements, a thorough review of thespecification is held with your project team.Page 28 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Detailed Hardware/Software Design & ProcurementBased on the functional specification,the project engineering team proceedswith four main tasks:Software DesignControl engineers use tool and utilitysoftware to configure the level 1controller logic, sequencing, and drives.The adjacent illustration shows a typicalfunction block diagram with logic inrelay format. The configurations areloaded into the controllers in the testlab.Process models for each mill functionare designed, configured, and put intothe level 2 computers.Operator Screen DesignOperator interface screens are designed,configured, and loaded into the pulpitHMIs and panel mounted touch screens.Hardware DesignAll equipment is specified per theproject requirements, and the powerdistribution system is designed. Acomplete set of elementary diagrams,layout, and outline drawings are created.Component ProcurementTMEIC works with its manufacturingplants and vendors to provide thehighest quality components for yourapplication.• Drives• Motors• Controllers and I/O racks• Computers and servers• Miscellaneous mechanical andelectrical equipmentEquipment Drawing, Toolbox Screen, and Operator Screen© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 29 of 40

Factory System TestA thorough integrated systemfactory test is extremely important.TMEIC has made an investmentin test technology and equipment.The TMEIC engineering teamconducts an exhaustive test in thelarge, fully-equipped system testlab, featuring:• Complete staging of the systemwith the controllers, servers,networks, HMI system, and alldrive controllers, which containthe controller board set, keypad,LAN interface, and I/O board.• Unique to the industry, the drivecontroller includes a motor andload simulator (refer to the nextpage for details) allowing lifelikesimulation of the mill operation.• Validation of all networkinterfaces to third-party PLCsand DCS systems.• Customer operators and theTMEIC commissioning teamare integrated into the factorytesting for training and feedback.The picture above shows one of the four test labs in our Virginia facility,which has an extensive selection of test equipment, including:• 200-plus drive controllers comprising the past 20 years of driveproducts• 64 HMI and touch-screen operator stations• 12 Innovation Series and V-Series controllersTypical Factory Test Setup in the LabControlServerHMIServerHMIOperatorTouchPanelsMasterControllerMachineControllerMachineControllerSimulatedI/ODrive Controller/SimDrive Controller/SimDrive Controller/SimMLoadMLoadMLoadMotor/Load Simulators on all TMEIC Drives (AC and DC)Page 30 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Industry Leading Process SimulationReal-World/Mill EnvironmentFactory Test SimulationLocal Area NetworksPower BridgeMotorLocal Area NetworksDigital MotorSimulatorDrive ControllerMLoadDrive ControllerM LoadDigital LoadSimulatorPowerPowerPowerDrive Cabinet,Controller,Power Bridge,& MotorMModelLoad ModelInertia K 1dN/dtFriction K 2NWindage K 3N 2In the Mill, the AC and DC Drives Control theSpeed of the Motor & Mechanical LoadEach AC drive has a controller with I/O and a gatedriver, which controls the power IGBTs in thepower bridge. The power bridge generates thevariable frequency AC voltage supply to the threephasemotor, controlling its speed and torque.In the case of a DC drive, the power thyristorbasedpower bridge converts the AC power to avariable DC voltage, which is applied to the motorarmature. This controls the DC motor’s speed andtorque.In the Factory System Test, the Drives Control aMotor & Mechanical SimulatorEach AC/DC drive in the system test has its owndigital motor simulator based on a dynamicmathematical model. The drives control thesimulators, not real motors. All drive simulatorsare networked with the controllers and operatorstations to test the entire system in real time.Starts, stops, speed changes, response to manualinputs, LAN continuity, control interaction, anddrive configuration are all validated.This unique capability allows the entire team toobtain an intimate understanding of the systemprior to the commissioning, ensuring a smooth,on-time startup.TransportDirectorScreenMill Process SimulationProcess inputs such as sensors, pyrometers, andload cells are simulated in the lab by the TransportDirector (TD). The same TD software can be appliedlater for control of the real process.The TD can be switched “on the fly” between realand process simulation modes. This allows for veryeasy implementation of Ghost Bar rolling whereonly the real metal is simulated, while real millequipment is being controlled (moved). Ghost Barfunctionality contributes to shorter startup periods,saves possible material losses and aids in systemand mill maintenance procedures.© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 31 of 40

System CommissioningIn the commissioning phase, the TMEIC teamincludes the field engineers you know and trust,alongside the engineer who designed and testedthe system. This overlap of teams between engineeringdesign and the site ensures a smooth andon-schedule startup.The TMEIC service engineer, who is responsiblefor startup and commissioning, and for any futureservice required at the site, is part of the projectteam and participates in the factory system test tobecome familiar with the system. Commissioning issupported by TMEIC design and service engineers.Commissioning PhasesCommissioning1. Oversee Installation ofElectrical Equipment: 2. Check Out all Wiring &- Motors - Controllers Communication Links, Load- Drives - Cabling & Wiring all Software, & Commissionthe Drives & Motors123. Mill Section Commissioningusing Shadow testing ifnecessary4. Entire Rolling Mill ControlSystem Commissioning usingGhost Rolling if necessary34Teams InvolvedCommissioning Time LineTMEIC offers a single source for installation and commissioning. Phases 2, 3, and 4 above are compressed by:• The exhaustive factory acceptance test that includes drives and control system functionality• Training and familiarization of the entire team with the system at the factory• Using shadow testing at the mill with system inputs (not outputs) connected to the operating plant• Using timesaving Wizards for commissioning and drive tune-up• Using ghost rolling to test the complete control system without rolling actual productsPage 32 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Drive Training at our Training Center or in Your FacilityCustomer engineers, maintenance and operationspersonnel are trained on the drives and controlsystem at the TMEIC Training Center in Virginia. Thisworld-class facility includes large classrooms andfully-equipped training labs.Classroom and hands-on training consists of 50%class time and 50% hands-on lab time. Topics include:• Overview of the drive system• Function of the main assemblies• Technical details of the components• Drive and control system tools• System diagnostics and serviceCustomized Training at the Customer’s SiteAs an alternative to the standard factory training in Virginia, TMEIC can offer a course tailored to your project andheld at your location. In this case, a project engineer trains your operators, maintenance technicians and engineersin your facility.Complete and Detailed Drive System DocumentationTMEIC delivers complete system documentation:• An electronic instruction book with all theprints on CD with a hyperlink index• System configuration on CD• Detailed system manual• Recommended wiring and groundingprocedures• Renewal parts list• Standard third-party vendor documentationAt the end of the project, the system drawingsare updated to reflect the final changesHard-Copy Documentation and Electronic Insturction Book© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 33 of 40

Global Customer Support NetworkComprehensive technical service is provided by our Customer Support Organization, staffed by TMEIC service engineerswith offices and spare parts depots across the globe.In North and South AmericaCustomers are supported by the TMEIC servicepersonnel, design engineers and Spare Parts Depotin Virginia, and the TMEIC Factory in Japan.In EuropeTMEIC service engineers service all drive systemsin Europe, supported by the European TMEIC SpareParts Depot.In Asia and the Pacific RimTMEIC services drive systems throughout China,India and the Pacific, supported by multiple FieldEngineers, Spare Parts Depots, and the TMEICfactory in Japan.Remote Drive DiagnosticsTMEIC supports drive customers through the RemoteConnectivity Module (RCM), a remote diagnosticservice link with the TMEIC design and serviceengineers in Roanoke, Virginia. The RCM enablesseamless integration between your drives and ourengineers.Remote System DiagnosticsTMEIC’s remote system diagnostics tool, includedin level 1 software, offers a quick path to problemresolution. System faults are automatically identified,and provide an integrated view of product, processand system information. TMEIC design and serviceengineers in Roanoke, Virginia, can analyze the dataand provide steps for resolution.For Service or Parts, call1-877-280-1835INTERNATIONAL:+1-540-283-201024 Hours / 7 daysRemote Diagnostic Service reduces Mean Time To Repair (MTTR)Remote diagnostic service offers protection for your investment, by reducing downtime, lowering repair costs andproviding peace of mind. Remote diagnostics requires an internet connection between your plant and TMEIC for retrievalof fault logs and files to diagnose drive or system issues.Features• Reduced downtime andMean-Time-to-Repair• Secured connection• Fault Upload UtilityBenefitsQuick support saves thousands of $ in lost productionTMEIC engineers can quickly connect to the drive and diagnose many issues ina matter of minutes.Customer-controlled accessAll remote activity is conducted with permission of the customer. Drive start/stop is not permitted remotely.Proprietary Fault Upload SoftwareHistorical drive faults are identified; TMEIC design and service engineers cananalyze the issue resulting in the fault and provide a solution.Page 34 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

ProductsA Family of AC & DC System DrivesTMdrive-10e2TMdrive-30TMdrive-70TMdrive-DCVolts3300 AC1250 ACTMdrive-30TMdrive-50TMdrive-80TMdrive-70690 AC440 ACTMdrive-10e21200 DC500 AC500 DC TMdrive-DC101001,00010,00013 134 1,34013,40020,00026,80050,00067,000kWHpFeaturesCommon Control HardwareAll TMdrive products share a common architecture:• Common I/O boards• Common LAN interface boards• Common front panel display and keypad optionsCommon ToolboxA common Windows®-based toolbox used to configureand monitor all TMEIC system drives featuring:• Integrated trending• Animated function block diagrams• Commissioning and tune-up wizardsBenefitsReduced Parts InventoryTMEIC reduces the spare parts investment with acommon set of control hardware for all of your lowvoltage AC, medium voltage AC, and DC systemdrives.Simplified MaintenanceCommissioning and tune-up wizards ensure thatthe system drives are not the critical path item inthe start-up. In ongoing maintenance work, theintegrated trending tools provide an in-depth viewinto the regulation functions.Legacy System InterfaceTMEIC system drives integrate with legacy systemsusing:• ISBus LAN interface for Innovation Series Controllerbasedsystems• Profibus-DP and DeviceNet LAN interface boards forother controller-based systemsReduced EngineeringThe majority of control system projects involve someform of modernization. The coordinated interfaces ofTMEIC systems to legacy system drives reduces thecost of engineering, commissioning, and training.© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 35 of 40

Operator InterfacesThe HMI provides operators, technicians, and maintenance personnel with a clear window into the operation ofthe mill and control system, with interactive real-time process control and drive data, plus trends for performanceanalysis. A typical rolling mill overview screen is shown below.Indicators forUpmill EquipmentStatusAlarmsPermissiveOverrideRun GhostMode at anyTimeLooper SpeedCorrectionSensor Status,Green is NormalRunout Table SprayCooling statusPermissive Indicators,click for detail popupscreensFM ExitSpeedNavigationButtons pull upSeparate ScreensWork Roll Bendingscreen, click WRBRoll Gaps screen,click Gaps buttonRoll Speed screen,click Speed buttonTrend RecorderScreen withhigh speeddata fromprocess(every 20 ms)and drives(every 1 ms)A Panel-Mounted Local Operator Station & Centralized HMI Interface areavailableFeaturesPanel-Mounted Touch ScreenThe compact, panel mounted touch screen providesa simple display and hardwired-like control action foroperator inputs such as start and stop.Machine Permissive DiagnosticsViewing the Boolean logic permissive block displayshows the contact preventing the machine sequencing.HMI Trend RecorderHigh-speed real-time and historic data from the controlsystem and drives is available on the HMI trend screen.BenefitsConvenient, Reliable Equipment Control PanelPanel-mounted close to the mill, the touch screenprovides an intuitive display and fast operator controlaction, plus rugged construction to stand up to themill environment.Faster Operator ResponseVisual diagnostics reduce the time to resolvepermissive logic problems and/or operator trainingissues.Convenient Drive and Process DiagnosticsThe high-resolution HMI screen trends live data fromthe controller and drive capture buffers for accurateprocess equipment performance analysis anddiagnostics.Page 36 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

nv Series ControllerThe Unified nv Series Controller‘s capabilities includehigh-speed logic, sequencing, motor speed control, andcontinuous control. High-speed I/O communicationuses the industry’s first 100 Mbps double loop network“TC-net I/O”, linking remote, field mounted I/O.The main features of this powerful controller are:• Redundant loop 100 Mbps I/O communication• Enhanced speed by direct execution of IECstandard control languages in ASIC hardware• Higher reliability using redundant modules, anderror checking and correcting ECC memory• Gigabit supervisory control networknv Controller board, upto three per chassisSecond nv Controller TC-net 100 board Ethernet boardPower supplyThird nvControllerInput/Output LAN TC-net I/O Loop, 100 MbpsInput/Output LAN TC-net I/O Loop returnSystem Network – Ethernet, 1 GbpsControl Network TC-net 100 – Fiber-optic, 100 MbpsFeatureHigh-speed processingShort control cycleLarge program capacityHigh data capacityInterruptsMultiple controllersProgramming flexibilityMemory reliabilityDetailsBit and integer processing: 20 ns; floating point add/multiply: 120 nsThree separately scheduled periodic tasks: 0.5 ms to 1,000 msPrograms up to 256 kilo steps (instructions), up to 385 periodic programsLocal/global variables 256 K words; I/O variables 16,384 16-bit wordsTotal of 16 interrupt tasksUp to three controllers per chassis; up to 4 communication modules; redundantcontroller and network configurations possibleFour IEC 61131-3 standard languages: LD, FBD, SFC, and STAn error-correcting ECC circuit in the internal memory of each module© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 37 of 40

TMdrive-Navigator - Simple Configuration and MaintenanceThe TMdrive-Navigator tool helps youmaintain TMEIC drives yourself. Engineersand technicians are empowered tounderstand how the drive works and whatthe drive is doing. Any user can easilyaccess current drive expertise and knowhow.Desk-top like search technology links topicalsignal lists, block diagrams, help files, productdocumentation, change history, and user notes.Windows techniques facilitate navigationwithin a drive and across the system. Thestatus of all drives is always in view.High-speed data is automatically captured andsaved in the event of a drive fault. Users mayalso capture high speed data based on their owntrigger conditions or perform high resolution realtimetrending.Fault data can be automatically “pushed” to keyusers. The client-server architecture allows accessto high performance data from remote locations– with the same resolution as if you were in theplant.Wizards support tuning of drive functions.Live block diagrams provide a real-timegraphical view of drive functions. Functionscan be configured directly from the graphicalview. Product documentation is integratedright into the tool. Users may evencapture their own notes to benefit futuretroubleshooting. Compatible with:• Windows XP, Vista 7• Windows Server 2003, 2008Page 38 of 40© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.

Mill Level 2 Software and ModelsLevel 2 provides mathematical process models and the required software infrastructure for them to function. Level2 distributes references to the level 1 controllers in a timely manner, and receives process feedbacks for modelupdates and data collection. Typical level 2 functions include:• Material tracking through process zones• Distribution of references• Process feedback scans and process setups• Production logging• Engineering logging• Performance classification and reportsSoftware and hardware (if necessary) is split into two basic parts: process control (executables) and data storage(databases).StatisticalAnalysis &ReportingDevelopment OfficesSimple SQLDatabaseQueriesModelTablesDBProcess HistoryDBProcess models functionality is presented in the application sections of this brochure. The following are basic andcommon features of level 2 and models software, and the customer benefits.FeaturesOpen ArchitectureThe hardware platform is based on industrial standards(PC servers), software platform C++, open communicationlinks via Ethernet, and database (MS SQL or Oracle)accessed via ODBC.Structured Software ProductsBased on OOD and OOP concepts, the suite of softwareproducts is fully configurable. The functions areconfigured for various applications, NO CODE CHANGESare required.Platform Independence and Distributed ComputingThe same source of software products is used for variousOS platforms: Windows, OVMS, or Linux. The sameapplications can run on the centralized computer or canbe distributed onto various units as required.Customer Benefits of Level 2 Software and Models• High product quality• Low cost of system ownership• Simple maintenance and troubleshootingBenefitsScalabilityThe software products can be simply “instanced” andadded to the application software for easy expansion.Cohesion of all Control LayersThe concept of global signals (Signal Data Base) andcentral data structure definition (data Dictionary DB)simplifies the system design and maintenance.Comprehensive Analysis Tools and ReportingSystem diagnosis utilities allow monitoring ofprocess execution and detailed communicationdiagnostics. Process data can be accessed via ODBC,analyzed, and reported using standard applicationssuch as: Excel, Access, MathCAD, and Statistica.• Minimum downtime• Short system startup and tune-up• Comprehensive reporting & record keepingsystem© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan. All Rights Reserved.Page 39 of 40

Worldwide NetworkGlobal Supplier of Drive & Automation SystemsTMEIC is built on the combined and proud heritageof Toshiba and Mitsubishi-Electric (TMEIC) in theindustrial automation, control and drive systemsbusiness. Headquartered in Roanoke, Virginia, USA,TMEIC Corporation designs, develops and engineersadvanced automation and variable frequency drivesystems.The factory for the World’s factoriesTMEIC delivers high quality advanced systems andproducts to factories worldwide, while serving as aglobal solutions partner to contribute to the growthof our customers.A Global networkTMEIC’s global business includes more than 2,200employees, with sales exceeding U.S. $2.4 billion, andspecializes in Metals, Oil & Gas, Material Handling,Utilities, Cement, Paper and other industrial markets.Customer ServiceWe focus on the customer, working to providesuperior products and excellent service, deliveringcustomer success every project, every time.Global Office Locations:TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMSCORPORATIONMita 43 MT Bldg.13-16 Mita 3 chome, Minato-ku Tokyo108-0073 JapanTel.: +81-3-5441-3828 Fax: +81-3-5444-3820Web: www.tmeic.co.jpTMEIC CorporationOffice: 1325 Electric Road, Suite 200Roanoke, VA, United States 24018Mailing: 2060 Cook DriveSalem, VA, United States 24153Tel.: +1-540-283-2000 Fax: +1-540-283-2001Email: metals@tmeic.comWeb: www.tmeic.comTMEIC Industrial Systems India Private LimitedUnit # 03-04, Third Floor,Block 2, Cyber Pearl, HITEC City, Madhapur,Hyderabad, 500081, Andhra Pradesh, IndiaTel.: +91-40-4434-0000 Fax: +91-40-4434-0034Email: inquiry_india@tmeic.comWeb: www.tmeic.inTOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS(Beijing) CORPORATION21/F., Building B, In.do Mansion48 Zhichunlu A, Haidian District,Beijing 100098, PRCTel.: +86 10 5873-2277 Fax: +86 10 5873-2208Email: sales@tmeic-cn.comTMEIC Europe LimitedUK (London) Tel.: +44 870 950 7220Italy (Bari) +39-080-504-6190Germany (Frankfurt) Tel: +49-6968-194722Poland (Krakow) Tel: +48-12432-3400Email: info@tmeic.euWeb: www.tmeic.comTMdrive is a registered trademark of Toshiba Mitsubishi-Electric Industrial SystemsCorporation.TMEIC is a registered trademark of Toshiba Mitsubishi-Electric Industrial SystemsCorporation.TM is a registered trademark of Toshiba Mitsubishi-Electric Industrial SystemsCorporation.All other products mentioned are registered trademarks and/or trademarksof their respective companies.All specifications in this document are subject to change without notice. Thisbrochure is provided free of charge and without obligation to the reader or toTMEIC. TMEIC does not accept, nor imply, the acceptance of any liability withregard to the use of the information provided. TMEIC provides the informationincluded herein as is and without warranty of any kind, express or implied,including but not limited to any implied statutory warranty of merchantability orfitness for particular purposes. The information is provided solely as a generalreference to the potential benefits that may be attributable to the technologydiscussed. Individual results may vary. Independent analysis and testing of eachapplication is required to determine the results and benefits to be achieved fromthe technology discussed. If you have any questions regarding your projectrequirements, please contact TMEIC at 540-283-2100.© 2011 Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan.All Rights Reserved.I-1010-A4