FIELD OF THE INVENTION
The present invention relates to an improved automation system adapted for reducing coil
telescopicity in re-coilers. More particularly, the present invention relates an improved system
adapted for correcting the deviation of lateral movement of the strip/coil from the
reference/actual position.
BACKGROUND AND PRIOR ART OF THE INVENTION
Research & Development Centre for Iron and Steel (RDCIS), Ranchi and Bokaro Steel Plant
(BSL), Bokaro have designed and installed modified edge guide systems in tension reels of
Pickling Line #2 (PL #2), Cold Rolling Mill, BSL, Bokaro.
Pickling line # 2 of Cold Rolling Mills(CRM), Bokaro Steel Plant, Bokaro is hydrochloric acid
based line for removing oxide layers of the hot rolled coils (HRC). It is equipped with two
numbers of tension reels for re-coiling the HR coils processed through pickling line. The existing
tension reels were incorporated with Edge Guide System (EGS) based on mechanical links
leading to slow system response and irregular wrapping of coil. The output coil quality was not
good i.e. uneven edges causing problem at downstream continuous processing lines. Moreover,
coils having telescopicity i.e. improper coil sidewall get damaged during handling by cranes.
This leads to generation of damaged and defective coils resulting in revenue loss.
To attain proper guiding accuracy on the exit end coils on a continuous processing line, the
guiding system should sense as well as respond accurately. The existing edge guide system
was being somehow managed by vigorous shop maintenance and frequent breakdown caused
line delay and production loss in downstream lines. The coils were processed without the
guiding system that led to generation of damaged and defective hot rolled pickled coils. To
overcome the loss due to generation of telescopic coils and decreased line availability, it was
decided to introduce quick-response integrated modified re-coiler edge guide system (armless
type), in place of the existing fixed arm type edge guide system.
US 3,786,974 discloses an apparatus for limiting the maximum lateral web shift initiated by a
web guiding system to a predetermined safe amount. A first web edge sensor adjacent the
supply roll senses deviations from a normal web edge position and generates a correction
signal which causes a servo-drive system to axially move the web supply roll in a direction to

return the web to its normal position. A second web edge sensor longitudinally spaced along the
web from the first sensor senses the web edge, and in response thereto positions stop
members which limit corrective lateral shift of the first edge sensor to a predetermined safe
amount.
US 6,600,507 discloses a system and method for tracking belts disposed on rollers in a
photoreceptor apparatus. The system includes a movable, belt edge guide that operates in
combination with an encoder, a belt edge sensor, a belt hole sensor for detecting a hole in the
belt surface, wherein the profile of the edge of the belt is learned as a function of the belt
position on the rollers. The encoder and belt hole sensor are used to actuate the edge guide
system to compensate for the contours of the belt edge and to maintain a constant lateral
position of the belt at any given point on the belt.
W01994008272 discloses a method and apparatus for guiding multiple layers of a liquid down a
hopper slide (23) surface are disclosed. The continuous edge guide includes an edger arm (20)
extending across the length of the slide surface (23) and having a side facing the slide surface
(23). A continuous edge pad (22) is abutted to the contact side which sealingly mates with the
slide surface (23). The continuous edge guide is capable of being positioned anywhere across
the width of the slide surface. In one embodiment biasing means (31) are positioned along the
edger arm to force the edge pad into contact with the slide surface. In an alternate embodiment,
the edge pad has a slot at a point above the first or second hopper element to provide good
contact between the edge pad and slide surface.
The present inventors have found an improved system for reducing the coil telescopicity is a
quick-response integrated modified re-coiler edge guide system (armless type), which has
replaced the existing fixed arm type edge guide system to overcome the loss due to generation
of telescopic coils and decreased line availability.
The proposed invention is for the system in totality i.e. design of the EGS based on the design
parameters of the processing line, selection of critical components like servo valve, hydraulic
cylinder, filters, etc., development of control philosophy and algorithm for optimal performance
of hydraulic power pack unit, user friendly fault diagnosis of the system, continual system
monitoring facility and remote operation facility.

OBJECTS OF THE INVENTION
One object of the present invention is to overcome the disadvantages / drawbacks of the prior
art.
A basic object of the present invention is to provide improved automation system for reducing
coil telescopicity in re-coilers
Another object of the present invention is to provide an improved system adapted for straight-
edge coiling of flat steel products on re-coilers to reduce coil telescopicity.
Yet another object of the present invention is to provide an improved system that facilitates
trouble free handling and processing of output coils at downstream continuous lines.
Yet another object of the present invention is to provide an improved system that eliminates
production delays, ensures good quality output coils and conceptualized taking into
consideration its adaptability under different shop requirements and logistics.
These and other advantages of the present invention will become readily apparent from the
following detailed description taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
According to one of the aspect of the present invention there is provided An improved
automation system adapted for reducing coil /steel strip telescopicity in re-coilers , said system
comprising :
a frame means substantially placed on a roller table means;
at least one sensor means mounted on said frame means and said sensor means is
substantially positioned close to the outer edge of said steel strip adapted to travel across the
strip width to detect deviation in the lateral movement of said strip edge from a predetermined
position;
at least one optical detector receiver substantially placed at an angle to the said sensor means
to measure the actual deviation of the strip edge from the predetermined position;
atleast one source means substantially placed parallel to said sensor means, said source
means is adapted to detect light emitted by said sensor means and said optical detector means
atleast one transducer means mounted with re-coiler adapted to transmit analogue signal of the
predetermined position of the lateral movement of said strip of the recoiler;
a hydraulic cylinder mounted on said re-coiler;
a hydraulic power means operatively connected with said cylinder means, said power means
comprising valve manifold and
atleast one valve means which is high response operatively connected with said valve means;
a hydraulic power panel is operatively connected with said hydraulic power pack adapted for
proper control, monitoring and user friendly fault diagnostic of said hydraulic power pack; and
a controller means operatively connected with said emitter , sensor means and transducer
means , said controller receives the output of sensor means and output of said re-coiler's
transducer and compares the output of sensor means and output of said re-coiler's transducer
to determine the mismatch between the two signal outputs to generate corrective signal, said
corrective signal generated from said controller means is sent to said hydraulic servo valve
adapted to send high pressure oil to said cylinder adapted to return the strip into the pre-
determined position.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates an improved automation system adapted for reducing coil
telescopicity in re-coilers.
or controller receives feedback signal from stroke transducer attached to the re-coiler, sensor
positioner and light source to generate corrective signal in case of lateral movement of steel
strip.
Particularly, the sensor of the system has been mounted on a structural frame fixed over the
roller table in such a manner to cover the wide range of coil widths.
The roller table is situated below the steel strip on which the strip travels either in the forward or
reverse direction. The roller table is a series of non-driven rolls which supports and aids strip
travel in the longitudinal direction. The same is not shown in Fig. 1.
The function of the sensor positioner is to generate the reference signal with respect to preset
value. The optical detector sends the actual signal value depending on the position of the coil
edge while moving on the roller table. The high frequency light source emits the light to be
detected by the sensor & optical detector.
The correction signal is sent to the servo valve mounted on the manifold with components such
as DC valves, safety valves, etc. Based on the analog signal received by the servo valve, high
pressure oil is sent to the hydraulic cylinder to correct the lateral position of the re-coiler. The
remote control desk is installed in the operator's pulpit and designed for remote operation of the
system.
Regarding functional efficiency, the system is being regularly used by Cold Rolling Mills, Bokaro
Steel Plant for defect-free coiling of hot rolled pickled coils. The system has been able to
achieve lateral displacement within the desired accuracy limit of 1 mm.
• Design of appropriate hydraulic power unit /power pack
The accuracy of edge guide system is dependent on response of re-coiler to laterally align itself
with the correction signal from the controller. The re-coiler lateral movement is controlled by the
correction speed of the hydraulic cylinder. Taking into account the average line speed of 450
m/min and desired correction speed of 30 mm/s, the hydraulic power unit was suitably designed

for achieving the optimum pressure and flow requirement. Additionally, High response ServoJet
valve was selected which was compatible with the required pressure drop and flow
requirements.
To continually sustain the pressure and flow parameters, hydraulic oil cleanliness was assigned
prime importance and necessary on-line filtration system has been incorporated to maintain
cleanliness level at minimum NAS 5. Regular filter maintenance schedule is diligently followed
to maintain the system in sound health.
The high pressure drop across the servo valve (A p=70 bar) leads to generation of heat in
hydraulic oil. To compensate the heat generation, suitable water-cooled plate type heat
exchanger has been incorporated in the recirculation circuit of hydraulic oil to maintain the
temperature in the working range. Recirculation unit and heat exchanger has been designed
and mounted on the power pack unit. The oil tank and the pump and recirculation motors are
designed in keep in view all the safety aspects.
The feedback of temperature, pressure, oil level, etc. is also obtained and displayed for
continuous monitoring of the system.
• Development of algorithm for control of power pack based on shop logistics
It is a software based control uploaded to microcontroller which is installed separately in the
power pack panel.
Algorithm developed for control of hydraulic power pack based on temperature, pressure, oil
cleanliness and oil level inputs from hydraulic power pack.
Soft timers provided in the logic between the start of the pump motor, relief valve & directional
control valve for smooth operation of hydraulic cylinder.
User friendly fault diagnosis of the system provided with LED indications.
Design of mounting and protection arrangement for sensors and light source

The location and mounting of sensor detector and light source plays an important role in
sensing lateral deviation of incoming strip edge. The distance between light source and sensor
detector has been kept optimally to eliminate any unwanted interferences. The steel framework
for mounting of sensors and positioner is compact and sturdy and provided with suitable
dampeners to eliminate vibration generated from roller table drives.
Considering the steam and acidic fumes prevalent in pickling line environment, suitable
structural modifications were carried out and cover / canopy provided for protection of light
source and sensor detector.
As the sensor travels across the strip width to accommodate varying widths, proper machining
of structural members has been done to avoid any jerks during movement of sensors across the
width of strip.
The following design parameters were taken into consideration in designing the improved and
modified edge guide system.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
Other features as well as the advantages of the invention will be clear from the following
description.
In the appended drawing:
Figure 1 illustrates schematic block diagram of re-coiler edge guide system.
Figure 2 illustrates hydraulic circuit diagram.
Figure 3 illustrates schematic arrangement of re-coiler edge guide system.
DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWING
In the following detailed description, reference is made to the accompanying drawings that form
a part hereof, and illustrate the best mode presently contemplated for carrying out the invention.
Further functioning of the system has been discussed below to describe the way the mechanism
operates. However, such description should not be considered as any limitation of scope of the
present system. The structure thus conceived is susceptible of numerous modifications and
variations, all the details may furthermore be replaced with elements having technical

equivalence. In practice the materials and dimensions may be any according to the
requirements, which will still be comprised within its true spirit.
The improved edge guide system for re-coilers has been designed and installed in tension reels
of Pickling Line #2 (PL #2), Cold Rolling Mill, BSL, Bokaro and the like. The system mainly
consists of high response servo valve with dedicated power pack and strip edge guiding system
with electronically synchronized sensor and recoiler movement.
The schematic arrangement of the present system has been given in Fig.-1.
The system consists of a light emitter and sensor mounted on a structural frame with provision
for positioning the sensor at suitable location depending on the strip width. The high frequency
alternating light sensing equipment, which is impervious to ambient light, allows detecting the
edge of the strip from its reference position. The structural frame with sensor is placed as close
to the outer diameter of the coil to attain a real-time closed loop proportional control
Any lateral deviation of the strip from the reference position is detected by the sensor and
transmits an analog output to the electronic controller which is proportional to the lateral position
of the strip edge. The linear stroke transducer, mounted to the re-coiler, simultaneously
transmits an analog output to the electronic controller which is proportional to the lateral position
of the re-coiler.
The electronic controller compares the output of sensor to the output of re-coiler's transducer.
Any mismatch between the two signal outputs, activates the hydraulic servo valve which moves
the hydraulic cylinder of the tension reels accordingly, so that the strip is returned to the position
pre-selected on the sensing equipment.
As illustrated in fig 1 the Equipment specification are as mentioned below:
The structural features as illustrated in fig 1 is given below:
Structural frame (1)
Light emitter (2)
Optical Receiver (3)
Sensor Positioner (4)
Stroke Transducer (5)
Servo valve (6)
Valve manifold (7)
• Sensor positioner
The sensor positioner is designed to detect automatically the strip edge by means of the
receiver and is suitable for the strip width 650 - 1250 mm as given in design basis.
• High frequency light transmitter /light emitter
High frequency light transmitter has been selected based on frequency requirement to
eliminate ambient light, size, shape, space considerations etc. The light transmitter has
been provided with suitable protection to avoid damage. It should be easily replaceable.
• Digital strip position controller
Microprocessor based electronic controller provides all functions necessary to
accommodate a wide range of guiding applications. It has simple menu driven set-up. Its
function is to drive an electro-hydraulic servo valve or the input of a power amplifier for
electro-mechanical applications. It has appropriate enclosures and mounting
arrangement.
• Optical detector receiver
It senses the material position in the edge guide application. It has a rugged enclosure to
protect against the acid fumes.
• Stroke transducer

The longitudinal stroke transducer is potentiometer type for giving the feedback signal of
the actual cylinder movement.
• Servo valve with connector
The servo valve has been selected based high dynamic response requirement of the
system. It is a two stage servo valve with servo jet pilot stage. The spool of the main
stage is drive by a jet pipe pilot stage in an electrically closed loop. This servo valve is
with integrated electronic with 24V DC power supply requirement.
• Hydraulic Power Pack
The material of construction of the tank of hydraulic power pack is off SS 316. It has
pressure filters, temperature indicators, plate type heat exchanger, recirculation pump
motor, main pump motor, limit switches, check valves, air breather, suction filter, oil level
indicator, temperature gauge, oil level switch, return line filters with mechanical dirt
indicator. The design of the hydraulic power pack has been on the basis of flow and
pressure requirement for system.
The power pack was designed keeping in view the system pressure, flow, oil cleanliness
and monitoring requirement. This design is system specific only.
• Hydraulic Power Pack Panel
The Hydraulic Power Pack Panel has been designed to operate the hydraulic power
pack. The system can run on AUTO mode from the remote control desk in the operator's
pulpit. The algorithm has been incorporated in the Microprocessor based control card
installed in the panel. This algorithm takes care of the various interlocks provided for the
smooth running of the power pack and to give jerk-less operation for cylinder movement
soft timers have been provided between the start of the motor and opening of the
directional valves. Various LED indications have been provided for the operator's friendly
fault diagnostic.
The soft timer is a part of control logic developed and uploaded in the micro controller.
• Remote Control Desk
The Remote control desk, installed in the operator's pulpit is designed for remote
operation of the system. The remote control desk has all facilities necessary like
switches / push buttons for Auto / Manual, Reel shift : left /right, reel centre, system
error, system start, etc. and display for lateral shift of sheet either through deviation
meter or display.
• Hydraulic cylinder
The stroke of the selected cylinder is able to correct strips of varying width from 650 -
1250 mm. Mounting of the selected cylinder has been designed to match the existing
cylinder mounting in order to avoid any modification in the existing set up for mounting
the new cylinder.
• Manifold with components
It has been designed to supply oil at required pressure to alternate lines connected to
servo valves. This is to ensure functioning of the EGS in the event of any breakdown in
either of the systems.
Fig. 2 describes the hydraulic circuit which suitably complements the quick response desired
from the EGS i.e. instantaneous corrective action of the re-coiler.
The hydraulic circuit is drawing based on which the hydraulic power pack has been
manufactured and basically describes the path of oil flow. The components are essential for
smooth and sequential operation of the power pack. This circuit is not in the hydraulic power
pack panel.
WE CLAIM
1. An improved automation system adapted for reducing coil /steel strip telescopicity in re-
coilers , said system comprising :
a frame means substantially placed on a roller table means;
at least one sensor means mounted on said frame means and said sensor means is
substantially positioned close to the outer edge of said steel strip adapted to travel
across the strip width to detect deviation in the lateral movement of said strip edge from
a predetermined position;
at least one optical detector receiver substantially placed at an angle to the said sensor
means to measure the actual deviation of the strip edge from the predetermined
position;
atleast one source means substantially placed parallel to said sensor means, said
source means is adapted to detect light emitted by said sensor means and said optical
detector means;
atleast one transducer means mounted with re-coiler adapted to transmit analogue
signal of the predetermined position of the lateral movement of said strip of the recoiler;
a hydraulic cylinder mounted on said re-coiler;
a hydraulic power means operatively connected with said cylinder means, said power
means comprising valve manifold and
atleast one valve means which is high response operatively connected with said valve
means;
a hydraulic power panel is operatively connected with said hydraulic power pack
adapted for proper control, monitoring and user friendly fault diagnostic of said hydraulic
power pack; and
a controller means operatively connected with said emitter , sensor means and
transducer means , said controller receives the output of sensor means and output of
said re-coiler's transducer and compares the output of sensor means and output of said
re-coiler's transducer to determine the mismatch between the two signal outputs to
generate corrective signal, said corrective signal generated from said controller means is
sent to said hydraulic servo valve adapted to send high pressure oil to said cylinder
adapted to return the strip into the pre-determined position.
2. System as claimed in claim 1 wherein said sensor comprises a cover means enclosing
the sensor for protection.
3. System as claimed in claim 1 wherein said strip width is of 650 mm to 1250 mm.
4. System as claimed in claim 1 wherein said strip thickness is of 1.20 mm to 5.00 mm.
5. System as claimed in claim 1 further comprising remote control desk positioned in the
remotely to the system adapted for remote operation of the system.
6. System as claimed in claim 1 said hydraulic power panel comprising a processor means
adapted to provide various interlocks for the smooth running of said power means .
7. System as claimed in claim 6 said processor means comprising microprocessor means
based control card.
8. System as claimed in claim 7 wherein said microprocessor means comprising soft
sensor means adapted to provide jerk less operation for cylinder means movement.
9. System as claimed in claim 1 said roller means comprises a series of non-driven rolls
adapted to support and aid the travel of said strip means in the longitudinal direction.
10. System as claimed in claim 9 said roller means is situated below said strip means
adapted to assist said strip to travel in either reverse or forward direction.
11. System as claimed in claim 1 wherein said hydraulic power means comprising at least
one oil cooling and filtration system ;
monitoring instruments adapted for continuous monitoring of said power means and
plurality of pump motor set.
12. System as claimed in claim 1 wherein said cylinder is operatively connected with said
valve means .
13. System as claimed in claim 1 wherein said valve manifold means adapted to supply oil
at required pressure to alternate lines connected to said valve means.
14. An improved automation system adapted for reducing coil /steel strip telescopicity in re-
coilers as herein substantially described and illustrated with the accompanying drawings.

The present invention relates to an improved automation system adapted for reducing coil /steel
strip telescopicity in re-coilers . The system comprising a frame means (1) substantially placed
on a roller table means, at least one sensor means (4) mounted on said frame means (1), at
least one optical detector receiver (3) substantially placed at an angle to the said sensor means
(4) to measure the actual deviation of the strip edge from the predetermined position, atleast
one source means (2) substantially placed parallel to said sensor means (1) , atleast one
transducer means (5) mounted with re-coiler, a hydraulic cylinder mounted on said re-coiler, a
hydraulic power means operatively connected with said cylinder means where said power
means comprising valve manifold (7) and atleast one valve means (6), a hydraulic power panel
is operatively connected with said hydraulic power pack and a controller means .