CNC Technical Description

TECHNICAL DESCIPTION
WALDRICH SIEGEN
Heavy Duty CNC Roll Grinding Machine
ProfiGrind 2500
BOKARO STEEL PLANT
Attn.: Mr. B.B. Jha, AGM Design Bureau
Hot Strip Mill
Bokaro Steel City 827004
INDIA
Date:
Project
Responsibility:
Mr. Karl-Heinz Adamek

WALDRICH SIEGEN GmbH & Co. KG
Daimlerstrae 24 57299 Burbach Germany
0049 2736 493-331 Fax: 0049 2736 493-706
Email: Karl-Heinz.Adamek@Waldrich-Siegen.de
Representative: Mr. Kalyan Mukhopadhyay

Empire Machine Tools Empire House/Ground Floor
414, Senapati Bapat Marg. P.O. Box 16330
Lower Parel, Mumbai 400 013 INDIA
(0091) 22 - 4 93 37 40 Fax: (0091) 22-4 96 23 80
Email: empiremt@bom3.vsl.net.in
May 31, 2006
GENERAL INFORMATION
Table of Contents
1
TECHNICAL DESCRIPTION ...........................................................................................................3

1.1
Beds ......................................................................................................................................3
1.2
Headstock .............................................................................................................................3
1.3
Counterstay...........................................................................................................................4
1.4
Steady Rests (hydrodynamic)...............................................................................................5
1.5
Steady Rests (hydrostatic)....................................................................................................6
1.6
Grinding Carriage..................................................................................................................7
1.7
WALDRICH SIEGEN CP - Measuring System ...................................................................10
ProfiGrind Control PGC 10 Roll Grinder CNC Control System ............................................14

2.1
PGC 10 Controller Description............................................................................................14
2.2
Fully Automatic, Integrated Roll Grinder Control ................................................................17
2.3
Options for the PGC 10 Control ..........................................................................................21
2.4
Concave / Convex Continuous Path Grinding System .......................................................23
ACCESSORIES..............................................................................................................................27
3.1
B-axis ..................................................................................................................................27
3.2
Eddy Current System (EC) .................................................................................................29
ACCURACIES ................................................................................................................................31
May 31, 2006
TECHNICAL SPECIFICATION
TECHNICAL DESCRIPTION
To assist you in your selection of a roll grinder supplier, below is a listing of benefits
of WALDRICH SIEGEN engineering and design features:
1.1
Beds
Cross Section of Beds
1.2
Details of Design
Benefits
Two-piece bed casting design, onepiece workpiece bed with headstock

base, one-piece carriage bed; short
distance between adjustable wedge
shoes.
Machine maintains its accuracy over a

long period because rigid and separate
beds ensure that there is no influence on
the carriage bed when loading heavy
workpieces on the workpiece bed.
"Walk-on" telescopic way covers

(when the carriage is stationary).
The guideways are protected from harsh

outside environment; i.e. splashing water,
dirt particles, etc.
Headstock
Headstock
Details of Design
Benefits
Ribbed cast iron.
Exceptionally rigid and stiff.
Infinitely variable drive.
No gear steps and therefore an optimum

accommodation to the grinding technology.
May 31, 2006
Faceplate with floating driver.
Non-restrictive driving of rolls provides for

optimum roll surface finish.
Headstock drive motor.
Digital variable frequency AC-Motor (IP

54), highest balance class for vibrationfree motion.
Starting motor for higher workpiece

weights.
Starting inertia and friction are overcome

without overloading the main motor.
Headstock Starting Drive
1.3
Counterstay
Counterstay
May 31, 2006
1.4
Details of Design
Benefits
Manual adjustment in longitudinal direction and manual clamping on the

bed.
Easy adjustment for the compensation of

axial forces.
150 mm adjustment of hydraulic

counterstay live plate.
Less time for loading/unloading; less wear,

less adjustment on bed, reduced risk of
collision.
Steady Rests (hydrodynamic)
Hydrodynamic Steady Rest
Details of Design
Benefits
Two (2) jaw type.
Highest concentricity, roundness and

shape tolerances for grinding on roll necks.
May 31, 2006
1.5
Steady Rests (hydrostatic)
Hydrostatic Steady Rest (with chock support as Option)
Details of Design
Benefits
Bearing shell jaw type.
Highest concentricity, roundness and

shape tolerances for grinding on roll necks.
Hydrostatic
Higher roll weight possible

Lower initial breakaway torque
Principle Sketch of Hydrostatic
May 31, 2006
Principle Sketch of Hydrostatic and Hydrodynamic
1.6
Grinding Carriage
Z
B
Grinding Carriage (with B-axis as option)
Details of Design
Benefits
Longitudinal feeds :
6 - 9000 mm/min.
Full utilization of maximum feed rates for

auxiliary time-savings.
Surface cutting
45m/sec.
May 31, 2006
speed
up
to
High grinding quality and cutting performance as required in each application.
Grinding spindle secured eccentrically with hydrostatic bushing.
Wear-free operations at maximum load of

the grinding spindle, thus providing for
long-term precision even under heavy-duty
conditions.
Principle Sketch of Hydrostatic Bearing Housing for Grinding Carriage
Details of Design
Benefits
Hydrostatic lubrication (red marking)

of both longitudinal and cross
guideways and of the grinding spindle.
Wear-free operations at maximum load of

the grinding spindle, thus providing for
long-term precision even under heavy-duty
conditions.
NC-Axis Carriage with B-axis as Option (Principle Sketch)
Details of Design
Benefits
CNC-controlled roll barrel shape

grinding by a unique actuating
mechanism.
Quick and precise adjustment for grinding

of all profiles at unsurpassed accuracy.
Automatic grinding wheel retraction

in case of power failure.
Prevents damage to machine and workpiece.
May 31, 2006
Principle Sketch of WALDRICH SIEGEN Monobloc Design
Details of Design
Benefits
Single-piece upper carriage with hydrostatically lubricated guideways

and overgrips.
Exceptional rigidity with no carriage tilting.

Wear-free traversing and high performance grinding of rolls with a large diameter
range.
Automatic wheel approach.
Time-saving, operator independent operation provides a soft contact with the roll.
Infinitely variable and constantly

controlled wheel cutting speed and
maximum wheel speed limitation.
Ensures constant performance independent of grinding wheel wear while the

maximum permissible speed of grinding
wheel is controlled for operating safety.
Continuous infeed to compensate for

wheel wear.
Geometry of roll is maintained even during

heavy roughing operations.
The Z-axis drive consists of two

servo drives with rack and pinion,
each located at either end of the
lower carriage. The drives will be
electrical braced and run in master/slave mode. The measurements
will be carried out by a highresolution incremental transducer.
Zero backlash, due to the electrical bracing of the master/slave mode of the servo
drives.
Improved smoothness of running by deletion of the worm drive and shortening of
the drive track.
Higher feed rate in Z-direction (up to 12
meter/min) cycle time improvement.
The symmetrical arrangement of the
motors outwards on the lower carriage
improves the stiffness and avoids tilting
at the reversing points of the wheel.
May 31, 2006
Principle Sketch of Electronically Preloaded Drives (Z-Axis)
1.7
WALDRICH SIEGEN CP - Measuring System

Measuring equipment and measuring beam are mounted on top of the carriage for
measurement of roll shape, roll diameter, stock removal, concentricity and roundness in conjunction with the CNC control system.
The measuring beam is equipped with two (2) probes. This allows comparison between the programmed (rated) and the ground (actual) shape. The comparison
made between the rated and actual shape is the pre-condition to generate the "optimization grinding" features of the CNC control.
All measurements can be taken before or after the grinding process. Measurements
of diameter and stock removal can be done during grinding and are performed by
the outer probe.
Measuring System (CP - Type) (Principle Sketch)
May 31, 2006
10
Details of Design
Benefits
Highest accuracy.
Use of high resolution digital measuring

scales.
Automatic measurement.
All measuring beam movements (X1-axis)

and measurements are carried out automatically. The measuring arms are automatically moved until the measuring probe
tips come into contact with the roll.
Measurement during grinding process.
The outer measuring arm is operated during the grinding process to monitor stock
removal and roll diameter.
Reliability.
The measuring beam, arms and probe tips

are free of backlash, thus ensuring reliable
measuring results.
Versatility.
The following measurements can be

made:
Stock removal during grinding
Roll diameter during grinding
Diameter before and after grinding
Shape of the roll
Roundness of the roll
Eccentricity of the roll
Taper of the roll
Automatic alignment of the roll to be parallel with the carriage bed (optional)
Process integration.
The software of the roll measuring system

evaluates the measured data to optimize
the grinding process and prints out all results on request; thus, roll protocols are
established quickly, accurately and automatically.
May 31, 2006
11
Details of Design
Benefits
CP-Type Measuring System (Wheel-Side-Arrangement)
1.7.1
Measuring Device in Combination with the CNC

Most of the important features of the CNC control require interaction of a measuring
beam providing data feedback of grinding results to the CNC for comparison between rated and actual roll shape.
Features of our CNC in combination with the measuring beam are as follows:
Measurement of shape
Measurement of eccentricity
Measurement of out-of-round condition
Measurement of diameter
Measurement during the grinding process
Automatic grinding according to prorated stock removal
Automatic grinding according to prorated diameter of roll
Dual (mate) grinding of work roll pairs
Optimization grinding by comparison of rated and actual values
Automatic alignment of the roll to be parallel with the carriage bed (optional)
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12
Alignment of the roll (optional) (Principle Sketch)
Average eccentricity determined (A-B)/2

No taper influence (A-B)/2
Direct in-process measuring (1:1 relationship)
May 31, 2006
13
ProfiGrind Control PGC 10 Roll Grinder CNC Control System
Overview of PGC 10
Main operator panel:
On carriage with full multiple color TFT service.
Auxiliary operator panel:

(push button / electronic hand wheel)
on carriage to allow manual interface
Main Operator Panel
2.1
PGC 10 Controller Description

The operator station consists of a 15" TFT flat screen monitor with a resolution of
1024 by 768 pixels and a choice of an industrial keyboard or a panel with individual
push buttons. Clever hardware makes it possible for the connection between the
computer and the operator station to consist of only two coaxial cables. For large
grinders two of these operator stations could be installed.
May 31, 2006
14
PGC 10: Hardware System Manger
The I/O (input/output) is made up out of a daisy chained string of I/O modules, which
allows decentralized placing of these modules anywhere on the machine, drastically
reducing wiring. Fiber optical communication allows for extremely fast updates,
while interference from conventional copper wiring is eliminated. The update rate of
this so-called Light Bus is over 1 MHz.
PGC 10: Configuration Screen for all Axis (Totally Open System)
The software platform chosen is Microsoft Windows XP, with a real time extension.
This stable operating system is widely used and lots of software tools are available.
The operator interface (or GUI, Graphical User Interface) is specifically designed for
roll grinder applications, while the look and feel of the previous generation of PGC
May 31, 2006
15
10 control systems is preserved as much as possible. Visual Basic was chosen as

the programming language. The logical part of the control software consists out of a
mixture of structured text and function blocks. This PLC style programming environment is IEC1131 compatible.
Full functionality, comparable with the previous control systems, is achieved.
PGC 10: Online Movement of all Axes for Service Purpose
Online diagnostic system is included.
PGC 10: Real Time Extension for Operation Speed of 1 ms
May 31, 2006
16
2.2
Fully Automatic, Integrated Roll Grinder Control

Details of Design
Benefits
Controller
Still the only real single process computer

controller, excluding internal interfaces
Type
PGC 10, based on industrial PC, field bus

system with fiber optic cabling
Most advanced for
Full integration of
Operation
Including - with compatible roll measuring system
May 31, 2006
Real time calculations

Extremely high-powered
Super fast for corrections with up-dated
data per new wheel stroke
Very flexible for 'real pick-out programming' in menu techniques (no working
through given schemes)
High resolution graphics for plotter type
quality pictures, of course scaled
All functions, possibilities and capabilities of
chapters:
Concave / convex continuous path control
grinding system - CNC
Roll measuring and inspection system
By use of the one above mentioned process
computer
Fully automatic with 'auto screen'
Fully flexible programming also matrix
type
Programming with operator's guidance
(dialog) for all mentioned geometrical data
and texturing parameters as well as procedures for functions (sequences), menu
techniques in clear (no computer) language
Programming in 'choose and pick
method', no inflexible following of preset
procedures and rules is required
Help functions/screens are available
TFT monitor for operator's comfort including true graphics of high resolution
On-line respectively in-process measuring
operations with permanently updated, real
time data feed back for possible in-process
corrections and / or logical decisions automatic (adaptive control).
17
Details of Design
Benefits
Fully automatic grinding fault correction
Direct recording of the measured actual

curve in control computer; there, the ideal
input curve is compared against the measured curve, and these both curves are
automatically plotted (screen and printer).
The grinding correction is superimposed
based on the above results.
In-Process corrections
Thanks to the computer's fast rate of reaction, when measuring during grinding, an
actual correction curve will be calculated
and actuated during each of the return
grinding strokes.
Full graphics - plotter type
A multi-colored high power screen is used

for permanently monitoring the curves:
ideal - actual tolerance.
Grinding to tolerance
Upper and lower tolerance curve are preselectable; the shape grinding process is
automatically stopped once the actual
curve lies within the tolerance range and for
example the removal target is reached. The
next cycle then immediately continues.
Roll shape creation by the concave/convex,
continuous path CNC grinding control.
Operator Screen "Auto Cycle"
May 31, 2006
18
Details of Design
Benefits
Main operator's panel
With full multiple color TFT service

On carriage
Optionally on floor and on carriage
Auxiliary panel
On carriage to allow manual interference
High level diagnostics
Extensive 200 fault diagnostics down to

board level with code number and clear
language written explanation on TFT
Software programming
On main panel after passing code words to

reach different operating and / or service
levels
Program data back-up
Standard for 100 rolls (additional capacity

as option)
Extended by
RSMS interface via database on the roll

grinder control and CD ROM or network
Full TFT monitor for
May 31, 2006
Programming in menu techniques

Roll data monitoring on high resolution
multiple color TFT scaled presentation,
zoom window enlargement of curve sections
Manual data input via keyboard
Program recall by name
Extensive override screen for all
variable parameters
Program interruption, restart, repetition etc.
Special operator's help function (operator
calls control for help to know what to do
next, control answers in clear language)
19
Details of Design
Benefits
Help Function
Whenever the operator or maintenance man looses track of what to do next, he

pushes the Help function key. The control then gives clear language instructions
how to proceed. The instruction appears in the actual window.
Storage of
100 different, complete roll grinding programs to be recalled by program name

only, storage in control of each grinder,
matrix programming also with different
curve grinding programs
Functions
Longitudinal roll alignment

Roll coupling
Inspection cycle with report especially of
initial roll diameter
Parallel roll alignment incl. software alignment correction by use of superimposed
compensation taper to compensate for a
possible mechanical rest error
Plausibility control whether the chosen
program matches the loaded roll by position check-up of counterstay or steadies
Eddy current surface inspection with logic
about extent of surface damages (option)
Extension of the eddy current detection
with ultrasonic measuring
Wheel dressing cycle
Adjustment for constant cutting speed
May 31, 2006
20
Details of Design
Benefits
Grinding sequences with
Contour or shape as required incl. end relief cut grinding
By use of
All possible grinding parameters such as

roll, wheel, carriage speed, wheel infeed
etc.
Roughing: especially with continuous
infeed for stock/damage removal, or 'device for grinding high barrel ends'
Semi finish grinding: for dimensional corrections, matching of rolls
Finish grinding: for grinding (shape) fault
corrections 'on-line' use of measuring system
Sparking out: especially with continuous
finest infeed for polishing rolls obtaining a
critical surface finish
Measurements and inspections
Incorporated into the program whenever

and wherever wanted
Final measurement and inspection

report
As described under 'roll inspection' on tag,

on TFT, in central computer or on printer
Set back of all components
Into reference/home positions
The CNC control
Is an own development using readily available out-of-shelf components
Note:
It is obvious that all roll measuring functions require choosing the roll measuring and
inspection system if not already included in the basic scope of supply.
In case of fully automatic roll grinders, sometimes automatic roll loading / unloading
systems are required. We have developed different systems including roll storage
racks.
2.3
Options for the PGC 10 Control

Details of Design
Benefits
Control for taper grinding
Closed loop control of the X- and Z-axis of

the grinding carriage (cross and longitudinal) to allow grinding of all required tapers
having freely selectable lengths
May 31, 2006
21
2.3.1
Details of Design
Benefits
Control for spiral vent-a-nip groove

cutting - Optional extension for progressive spiral grooves available.
Closed loop control of the axes of headstock and carriage to allow thread cutting of
all required pitches
Control for eccentric compensation

grinding - Optional extension for
automatic data input available.
Grinding of the outer surface of a shell concentrically to its inner bore, by use of correction values.
Text on TFT screen bilingual

German / English and Chinese. The PC control system allows for different languages. In case you would like to have the different screens in Chinese language,
we will send over to the Buyer the respective text that has to be translated. Afterwards, we will implement your translation into the PC controller. In principle, this will
be done for all operator screens, not for service screens.
The basic language will be English or German as required by you.
2.3.2
Extended Diagnostics
The standard fault system provides excellent detection for over 200 possible faults
on the machine. An optional extended diagnostics system provides additional features that complement the standard fault detection system.
The extended diagnostics enhance the fault detection system by providing aids to
maintenance personnel when a fault is detected and extending the fault detection to
time-dependent failures which are not detectable by traditional fault detection systems.
In operation, this provides the extended features of displaying the complete logic
associated with the detected fault. This aid to maintenance provides on-line information in relay ladder form (graphically displayed on the operator's TFT). This means
that, once failures are detected, the time to resolve the problem is reduced.
Additional aids include tracing of selected inputs, outputs and flags and also the ability to scroll through the relay ladder logic. A clear text description and color indication of status of inputs, outputs and flags is also provided.
2.3.3
Scope View
Via a scope view system it is possible to view I/Os and flags as well as variables. In
the logbook the user actions, overrides, messages, faults PLC-messages and sequential function carts (SFC) messages are logged.
2.3.4
Possible To Interface With (Option)
Central roll shop computer (WALDRICH SIEGEN RMS),

Programming for roll grinding
Programming of software
Operating services
May 31, 2006
22
2.4
Monitoring services
Storage capabilities
SPC-capabilities
Roll history built-up
Roll tracking, scheduling
Full up- and downloading
Program back-up service
Your host (main frame) computer preferably through central roll shop computer
Concave / Convex Continuous Path Grinding System

The process computer controlled crowning system has been especially developed
by WALDRICH SIEGEN to fulfill the special demands of the industry. It is fully incorporated into the single process computer control of the roll grinder.
2.4.1
Highest shape flexibility

Easiest, graphically aided roll shape creation (GAC system) in menu techniques
and clear language dialog
Roll shape storage and automatic integration of the selected shape into the
grinding program
High level, on-line adaptive control capabilities for roll shape correction grinding,
roll alignment error compensation, machine bed misalignment correction
Highest availability by: high level diagnostics, use of readily available "off-theshelf" components
Roll Barrel Shape Flexibility

Details of Design
Benefits
Electronically range
Sinus curve
10 mm on radius
26 - 180 degrees angle section
Different Roll Shapes
May 31, 2006
23
Details of Design
Benefits
Shape variations using different sine

angle sections
Sine Curves with Different Chamfers
Barrel end relief to be ground in one

cycle with the roll barrel
One side or both sides, mirror
type or different
Multiple end relief sections are
possible
Compound: different sine curves

Tapers
Radiuses
Flat middle sections
Exponential/parabolic
Compound curves
From the above mathematical curves
CVC / CVCplus shapes
Input by coefficients formula up to seventh

degree
Required input data
Profile value:
a1: ..........................E6
a2: ..........................E9
ax:...........................Ex
a7: ..........................E24
Barrel start: ............mm
Barrel end: .............mm
Mirror:.....................yes/no
One-button mirror function for tope and
bottom rolls
Arc grinding
Empirical curves
May 31, 2006
Continuous path control by data point

input (station-to-station) - CVC etc.
Station-to-station raster: free choice of
interval raster
Circular interpolation
24
2.4.2
Correction Capabilities To Be Superimposed Onto Above Curves

Details of Design
Benefits
Guide path corrections input values

Grinding fault correction input values
Software correction of parallel roll
alignment
Station-to-station input 0.002 - 0.99 mm;

based on radius
Station-to-station input 0.0001 - 0.99
mm; based on radius
Compensation taper to compensate for
possible mechanical alignment error
Crowning range
The whole offered crowning range including

correction capabilities is worked through
the highly accurate eccentric U-axis.
Further tools for possible improvements:
Wheel width compensation - shifting continuously calculated, based on roll

shape profiling
Z-axis speed profiling for faster grinding
Amperage profiling continuously calculated based on empirical customer's data
for constant wheel pressure independent
of wheel width actually on roll
Z-axis reference point shifting
Multiplication factor for crown height correction
Working curve storage, feed forward correction based on empirical customer's
data
Grinding Wheel Width Compensation (Principle Sketch)
May 31, 2006
25
Details of Design
Benefits
Adaptive control.
In case of adequate roll inspection
system and automatic grinding package
Fully automatic grinding fault correction by

direct recording of the actual, measured
curve in the control computer; after a programmed measuring cycle, there, the ideal
curve is compared with the measured
curve, and the correction curve is automatically superimposed
Shape Error Correction (Principle Sketch)
May 31, 2006
26
ACCESSORIES
3.1
B-axis
For swiveling of the grinding wheel face for fast and precise CVC grinding.
Developed, designed and patented by WALDRICH SIEGEN, the B-Axis offers the
possibility to use a roll grinding machine at highest accuracy, exceptional surface
quality, reduced wheel wear and to achieve shortest grinding times. One reason for
its development was the high edge-wear when grinding roll curves with a large variety of diameters. (CVC-curves for example)
Standard (without B-axis)
with WALDRICH SIEGEN B-axis
Technical Advantages of the B-axis used on heavy Roll Grinders (Principle Sketch)
May 31, 2006
27
By using the B-axis WALDRICH SIEGEN roll grinding machines are capable to position the grinding wheel always vertically to the corresponding curve tangent, which
offers the following advantages:
Increase grinding machine performance in a cold rolling mill by up to 30 %
Reduced grinding times by using maximum machine performance
Reduced wear of the grinding wheel (and possibility to use harder wheels) and
increase of the grinding wheel contact area
Increase of the roll shape accuracy and simultaneous improvement of the surface quality.
Technical Data
Swiveling angle of grinding wheel to accommodate generated line
Swiveling angle...................................................................
deg.
0,225
Feedrate .............................................................................
deg./s
0,0833
Torque (servomotor) ...........................................................
Nm
Speed range .......................................................................
rpm
1 - 4000
Resolution...........................................................................
arcs
0,858 x10-5
May 31, 2006
28
3.2
Eddy Current System (EC)
3.2.1
Roll Inspection System

For all roll applications there is a request for an equipment to localize defects of rolls
for higher safety within the rolling mill, higher quality and optimized re-grinding purposes.
As a roll manufacturer you will use the equipment for ensuring and computerized recording of the quality of your rolls.
This continuous process in your roll shop for identifying and quantifying roll defects
will enable a grinder operator to remove the precise amount of material from a roll to
eliminate all detrimental defects before the roll is sent back to the mill.
The system can be installed on an existing grinder as a stand-alone unit or fully integrated into our grinder control. It is designed to minimize mill downtimes and lower
the operating costs for the mill.
With the real time identification of the defects on the surface of the roll, your grinder
operator is in the position to determine exactly the amount of material removal that
is required to render the roll acceptable for supply to mill or roll user.
Eddy current system
The eddy current roll inspection system can be used as follows:
Eddy current roll testing to check for surface defects, magnetism and bruises
Eddy Current (Principle Sketch)
3.2.2
Roll surface inspection

Eddy current roll surface inspection
The eddy current inspection system (EC tester) is used for checking the roll surface,
detecting cracks and chill cracks up to a depth of 3 mm, hardness increases and
hardness variations as well as magnetic fields. In order to be able to detect these
defects, they have to start at the roll surface.
May 31, 2006
29
The effective width of the eddy current inspection head is 40 mm (optional 13 mm).
The eddy current roll inspection can be carried out during the grinding process. With
several passes during the grinding process the complete surface of the roll is
checked.
Eddy Current Sensor
May 31, 2006
30
NOTES
ACCURACIES
Manufacturing and installation of our grinders are performed according to WALDRICH SIEGEN geometric acceptance regulations TKA 121 00 002 CP per German
DIN and ISO Standards.
Machine System Accuracy

(Accuracies below are based on radius)
Roundness .........................................................................
mm
0,001
Eccentricity .........................................................................
mm
0,002
Straightness of generated line............................................ mm/m
0,001
Taper (conical form) ........................................................... mm/m
0,0025
Shape accuracy (0,1mm height of crown) ......................... mm/m
0,002
May 31, 2006
31

CNC Technical Description

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TECHNICAL DESCIPTION

Mr. Karl-Heinz Adamek

Representative: Mr. Kalyan Mukhopadhyay

May 31, 2006

TECHNICAL DESCRIPTION ...........................................................................................................3

ProfiGrind Control PGC 10 Roll Grinder CNC Control System ............................................14

May 31, 2006

Cross Section of Beds

Two-piece bed casting design, onepiece workpiece bed with headstock

Machine maintains its accuracy over a

"Walk-on" telescopic way covers

The guideways are protected from harsh

Ribbed cast iron.

Exceptionally rigid and stiff.

Infinitely variable drive.

No gear steps and therefore an optimum

May 31, 2006

Faceplate with floating driver.

Non-restrictive driving of rolls provides for

Headstock drive motor.

Digital variable frequency AC-Motor (IP

Starting motor for higher workpiece

Starting inertia and friction are overcome

Headstock Starting Drive

May 31, 2006

Manual adjustment in longitudinal direction and manual clamping on the

Easy adjustment for the compensation of

150 mm adjustment of hydraulic

Less time for loading/unloading; less wear,

Steady Rests (hydrodynamic)

Hydrodynamic Steady Rest

Two (2) jaw type.

Highest concentricity, roundness and

May 31, 2006

Steady Rests (hydrostatic)

Hydrostatic Steady Rest (with chock support as Option)

Bearing shell jaw type.

Highest concentricity, roundness and

Higher roll weight possible

Principle Sketch of Hydrostatic

May 31, 2006

Principle Sketch of Hydrostatic and Hydrodynamic

Grinding Carriage (with B-axis as option)

Full utilization of maximum feed rates for

May 31, 2006

High grinding quality and cutting performance as required in each application.

Grinding spindle secured eccentrically with hydrostatic bushing.

Wear-free operations at maximum load of

Principle Sketch of Hydrostatic Bearing Housing for Grinding Carriage

Hydrostatic lubrication (red marking)

Wear-free operations at maximum load of

NC-Axis Carriage with B-axis as Option (Principle Sketch)

CNC-controlled roll barrel shape

Quick and precise adjustment for grinding

Automatic grinding wheel retraction

Prevents damage to machine and workpiece.

May 31, 2006

Principle Sketch of WALDRICH SIEGEN Monobloc Design

Single-piece upper carriage with hydrostatically lubricated guideways

Exceptional rigidity with no carriage tilting.

Automatic wheel approach.

Infinitely variable and constantly

Ensures constant performance independent of grinding wheel wear while the