Tata Steel, Sahibabad

Introduction

Tata Steel's Sahibabad unit, known for its excellence in Cold Rolling Mill (CRM) operations, has been a key supplier to the automotive sector since the 1990s. To produce blemish-free, high-quality cold-rolled strips, the precision and surface finish of rolls are critical. Recognizing this need, Tata Steel became one of the pioneers in India to install Waldrich CNC Roll Grinders at their Sahibabad plant, ensuring consistent and superior grinding quality.

‍

Problem Statement

By 2018, one of the Waldrich Roll Grinders faced significant challenges. The automation system had become obsolete, leading to frequent breakdowns and unavailability of technical support. The machine's declining performance posed a risk to roll quality and, consequently, the quality of the finished cold-rolled strips. To maintain operational excellence, an urgent upgrade of the Roll Grinder was imperative.

‍

Solution Approach

Tata Steel selected Maxis as its trusted partner for the comprehensive modernization of the Roll Grinder. Maxis implemented a state-of-the-art solution that encompassed:

1. Advanced CNC System Integration

Deployment of the Siemens Sinumerik 840Dsl CNC system, featuring advanced capabilities such as:

• Short Stroking: Enhancing precision and surface quality by minimizing unnecessary movements.
• Constant Current Grinding: Ensuring uniform material removal and consistent finish.

Integration of Sinamics S120 Drives and high-performance servo motors (1FT7/1FK7/1PH8 series) for seamless motion control and accuracy.

2. Electrical System Overhaul

• Replacement of old electrical cabinets with new, state-of-the-art enclosures.
• Installation of modern electrical accessories, power and control cables, and advanced field elements.
• Incorporation of sensors, limit switches, and other safety components for reliable machine operation.

3. Mechanical Reconditioning

• Machine Alignment and Bed Scraping: Conducted to restore micron-level precision.
• Grinding Spindle Assembly Replacement: Installation of a new spindle and bushes to achieve optimal performance.
• Integration of new transmission mechanisms, including ball screws and pulleys, ensuring smooth operation and longevity.

4. Online Roll Measurement System

Installation of a cutting-edge online roll measurement system that measures and compensates for key roll parameters, including:

• Misalignment
• Diameter (DIA)
• Roundness
• Taper
• Profile

This real-time monitoring ensures consistent grinding quality and minimizes rework.

‍

Conclusion

The modernization project was successfully completed in 2019. Since then, the upgraded Roll Grinder has been delivering consistently high-quality rolls, contributing to the production of superior cold-rolled strips. Tata Steel's commitment to technological advancement and operational excellence is evident in its proactive approach to machine upgrades.
Maxis continues to provide reliable support, ensuring that the machine operates at peak performance. This collaboration stands as a testament to how innovative engineering solutions can extend the life of critical equipment, optimize productivity, and maintain the highest standards of quality in the manufacturing sector.