Abstract: Disclosed is a novel split header for use in a rolling mill. The split header has a mounting block and a quick-change header cartridge, wherein the mounting block is coupled to the quick-change header via a quick-disconnect feature, the quick-disconnect feature configured to enable uncoupling (in a toolless manner) of the quick-change header from the mounting block. Additionally, the quick-change header cartridge may be replaced by a dummy header cartridge that diverts water when stand is dummied, and a split base and header cartridge design. Further, the mounting block may have one or more sensors and the quick-change header may have an RFID tag, where the sensors and the RFID tag may communicate with a central computer.

Abstract: Disclosed within are various embodiments that provide for an automated rod coil cutting station for both ferrous and non-ferrous wire rod mills.

Abstract: Disclosed within is a slit section pass formation unit having a pair of rolls and a de-ribbing means, where the pair of rolls has a roll profile configured to produce a pair of slit rods with symmetrical dimensions, the pair of slit rods connected via a rib, and the de-ribbing means to remove the rib in its entirety forming a first slit rod and a second slit rod.

Abstract: Disclosed is a novel split header for use in a rolling mill. The split header has a mounting block and a quick-change header cartridge, wherein the mounting block is coupled to the quick-change header via a quick-disconnect feature, the quick-disconnect feature configured to enable uncoupling (in a toolless manner) of the quick-change header from the mounting block. Additionally, the quick-change header cartridge may be replaced by a dummy header cartridge that diverts water when stand is dummied, and a split base and header cartridge design. Further, the mounting block may have one or more sensors and the quick-change header may have an RFID tag, where the sensors and the RFID tag may communicate with a central computer.

Abstract: Disclosed is a system for automating and optimizing coil formation in a wire rod cooling conveyor comprising: (a) a speed measuring device (e.g., a laser velocometer) measuring a speed of a material entering a laying head; (b) a processor that: (1) receives, as input, the speed measured in (a), (2) computes an optimal speed of the laying head based on the received speed of the material entering the laying head; and wherein the processor dynamically computes the optimal speed of the laying head as the speed of the material changes. Also disclosed is a camera that monitors actual ring formation on the wire rod cooling conveyor at an exit point of the laying head, wherein the processor receives such monitored information from the camera and outputs a control signal to override the speed measuring device and to adjust a speed of the wire rod cooling conveyor.

Abstract: Disclosed is a system for use in a rolling mill having: (a) a roll holder housing a plurality of rollers; (b) a smart module coupled to the roll holder, the smart module comprising: (1) a power source powering the smart module; (2) a microcontroller; (3) a motor, the motor, based on instructions from the microcontroller, controlling a position of the plurality of rollers by moving the roll holder; (4) one or more position sensors, the one or more position sensors detecting the position of the roll holder; and (5) a communication module, the communication module communicating with a central controlling computer to: (i) communicate the position of the roll holder and other sensor data to the central controlling computer, and (ii) receive instructions from the central controlling computer to control the position of the roll holder.

Abstract: An automated trimming system is provided that includes a vision system identifying the number of rings positioned within a coil and sheared positions where the rings need to be cut. One or more trimming mechanisms receive the sheared positions and proceed to cut the rings at the sheared positions. A hook arrangement interfaces with the coil for transferring the coil to a trimming area. Moreover, an automated trimming system is provided that includes a coil having a plurality of rings. One or more trimming mechanisms select a number of rings from the coil and proceed to form a sample of desired length, by cutting a portion of the rings. A receiver unit receives the sample from the one or more trimming mechanisms to evaluate the quality of the sample.

Abstract: Disclosed is a system for use in a rolling mill having: (a) a roll holder housing a plurality of rollers; (b) a smart module coupled to the roll holder, the smart module comprising: (1) a power source powering the smart module; (2) a microcontroller; (3) a motor, the motor, based on instructions from the microcontroller, controlling a position of the plurality of rollers by moving the roll holder; (4) one or more position sensors, the one or more position sensors detecting the position of the roll holder; and (5) a communication module, the communication module communicating with a central controlling computer to: (i) communicate the position of the roll holder and other sensor data to the central controlling computer, and (ii) receive instructions from the central controlling computer to control the position of the roll holder.

Abstract: Automated height control and coil formation in wire rod mills are described within, where improvements in vision systems and smart sensors are leveraged to enable real-time control of both coil formation and coil height, without the need for secondary inspection and operator input from the pulpit.

Abstract: A roll mounting system is provided that includes a roll assembly coupled to one or more rolls. The roll assembly is configured to position the one or more rolls using a tapered assembly for mounting or dismounting of the one or more rolls. Also, the roll mounting system includes a torque assembly coupled to the roll assembly. The torque assembly is configured to provide torque to the roll assembly for mounting or dismounting of the one more rolls.

Abstract: Disclosed within are various embodiments that provide for an automated rod coil cutting station for both ferrous and non-ferrous wire rod mills.

Abstract: A system for cooling rolling mill material is provided that includes a conveyor system that receives rolling mill material and passes the rolling mill material through one or more cooling regions. A cooling structure that operates uniformly across the central and edge regions of the conveyor system. The cooling structure uses a first jet of air for cooling the central portion of the rolling mill material. A nozzle deck is positioned on the edge regions of the conveyor system produces a second of jet of air for cooling the edge portions of the rolling mill. The nozzle deck includes one or more adjustable nozzle structures for controlling the air flow produced by the second jet of air by varying the size of their air passage regions.

Abstract: An autonomous vehicle is described for use as part of a fleet of such vehicles used in coil handling. The autonomous vehicle has an on-board processor communicating with an external processor (e.g., an Artificial Intelligence (AI) processor) to receive and execute one or more instructions for automated operation of the autonomous vehicle, a robotic drive to move the autonomous vehicle based on the instructions received from the external processor; and a set of gripping mechanisms receiving the instructions and operating in one of two coil storage modes: a vertical mode and a horizontal mode. The instructions instructing the autonomous vehicle to handle one or more of the following coil handling tasks to move a coil: moving the coil after a reform stage, moving the coil after a trimming/inspection stage, moving the coil after a compacting stage, and moving coil to a storage location.

Abstract: A roll mounting system is provided that includes a roll assembly coupled to one or more rolls. The roll assembly is configured to position the one or more rolls using a tapered assembly for mounting or dismounting of the one or more rolls. Also, the roll mounting system includes a torque assembly coupled to the roll assembly. The torque assembly is configured to provide torque to the roll assembly for mounting or dismounting of the one more rolls.

Abstract: A pouring reel for forming a hot rolled long product into an annular coil comprises a central mast lying on a vertical axis. A cylindrical tub surrounds and cooperates with the central mast to form an annular tub chamber. A coil plate defines a bottom of the tub chamber. The central mast, cylindrical tub and coil plate are rotatable in unison about the vertical axis. An entry nozzle has a delivery end arranged to direct the product downwardly into the tub chamber for accumulation on the coil plate as a series of superimposed rings forming the coil. The coil plate is movable downwardly along the vertical axis and relative to the central mast and the cylindrical tub to accommodate the increasing height of the coil being formed in the tub chamber.

Abstract: A combined iris and shear unit for a coil forming device is provided that includes an actuator and a plurality of support members coupled together in series to support formation of a coil and connected to the actuator. Each support member further comprises a retractable shear blade. The actuator adapted to cause movement of the support members between an open position with the blades of the combined iris and shear unit being retracted away from the reform tub wall, so that coil forming takes place within the reform tub without interference. A support position with the blades extends into the reform tub and providing support for the coil; or a shear position for cutting the coil before it is extracted.

Abstract: A pouring reel for forming a hot rolled long product into an annular coil comprises a central mast lying on a vertical axis. A cylindrical tub surrounds and cooperates with the central mast to form an annular tub chamber. A coil plate defines a bottom of the tub chamber. The central mast, cylindrical tub and coil plate are rotatable in unison about the vertical axis. An entry nozzle has a delivery end arranged to direct the product downwardly into the tub chamber for accumulation on the coil plate as a series of superimposed rings forming the coil. The coil plate is movable downwardly along the vertical axis and relative to the central mast and the cylindrical tub to accommodate the increasing height of the coil being formed in the tub chamber.

Abstract: A system is disclosed for vibrating a coil carried on a pallet, with the pallet being supported on and movable along a conveyor. The system includes an elevator mechanism for lifting and supporting the pallet in a raised position spaced above the conveyor. Vibration motors serve to vibrate the elevator mechanism, thereby also serving to vibrate the raised pallet and the coil carried thereon.

Abstract: A temperature control system used for cooling a rolling mill product is provided. The temperature control system includes a plurality of isolation valves that are directly coupled to one or more water boxes. At least one pump is coupled to the isolation valves. The at least one pump provides the pressure needed for cooling. The isolation valves are positioned to reduce the time required to build up pressure for cooling and reducing the metallurgical property transition length of the rolling mill product.

Abstract: A system for cooling rolling mill material is provided that includes a conveyor system that receives rolling mill material and passes the rolling mill material through one or more cooling regions. A cooling structure that operates uniformly across the central and edge regions of the conveyor system. The cooling structure uses a first jet of air for cooling the central portion of the rolling mill material. A nozzle deck is positioned on the edge regions of the conveyor system produces a second of jet of air for cooling the edge portions of the rolling mill. The nozzle deck includes one or more adjustable nozzle structures for controlling the air flow produced by the second jet of air by varying the size of their air passage regions.