ABB Millmate Rolling Mill Force Measurement System

System Overview

The Millmate roll force system is a high-precision roll force measurement solution designed by ABB specifically for rolling mills, used for roll gap setting, load distribution monitoring, and bearing and roll eccentricity monitoring.

Core principle: Presductor ®  Magnetoelastic effect (patented in 1954)

System composition: Millmate Controller 400+force sensor+matching unit

Applicable equipment: tropical rolling mill, cold rolling mill, pipe rolling mill, vertical rolling mill

Measurement principle (Presductor) ®）

The sensor is equipped with primary and secondary coils that form a 90 ° angle with each other, and there is no magnetic coupling when there is no load

After being subjected to force, the magnetic permeability of the steel changes, the magnetic flux becomes unbalanced, and the secondary induction is proportional to the voltage of the force

Advantage:

Stable output without pre tightening

Extremely strong overload capacity: 300% rated load without permanent deformation, 700% without damage

A single sensor contains 1500~2000 measuring units, which remain accurate even under uneven force

Output 500mV high signal with excellent signal-to-noise ratio

Force sensors (four types)

1. Circular PFVL141C

Range: 1.6~60MN

Installation: Under the screw/hydraulic cylinder of the rolling mill

Structure: Square iron core+hot sleeve stainless steel ring

Features: Uniform force distribution, simple installation and maintenance, no need for machine frame processing

2. Rectangular PFVL141V

Range: 0.63~60MN

Installation: Below the bearing seat of the lower support roller

Features: No operation required when changing rollers, customizable size (30mm module)

3. Circular PFVL141R

Range: 2.0~28MN

Installation: Press down the nut between the nut and the frame

Features: Small space occupation, good protection, suitable for compact racks

4. Small circular QGR104/102

Range: 0.1~2.5MN

Applicable: Small tube rolling mill, small vertical rolling mill

Key Performance Indicators

Parameter PFVL series QGPR series

Accuracy level ± 0.5% F.S. ± 1.0% F.S

Linear error ≤± 0.5% ≤± 1.0%

Lag error ≤ 0.2% ≤ 0.2%

Repeatability ≤± 0.1% ≤± 0.05%

Rated compression capacity 0.05mm 0.05mm

Working temperature -10~+90 ℃ -10~+80 ℃

Zero temperature drift ≤± 0.01%/℃ ≤± 0.005%/℃

Control System (Millmate Controller 400)

1. Model classification

PFVA 401: Compatible with PFVL sensors, 2/4-point configuration

PFXA 401: Compatible with QGPR sensors, 2/4-point configuration

Suffix F: with Profibus DP interface

2. Electrical specifications

Power supply: 85~264V AC, 47~63Hz

Analog quantity: 4 inputs/4 outputs (0~± 10V/4~20mA)

Digital quantity: 8 inputs/8 outputs (24V)

Communication: Ethernet (VIP), RS232, Profibus DP (optional)

Response: 1ms (PFVL), 5ms (QGPR)

Protection: IP20

3. Core functions

Preset measurement mode and sensor parameter table

Filtering time: adjustable from 1 to 2000ms

Multi unit switching: N, kN, MN, kp, t, lb, ton

Self diagnosis, sensor testing, simulation mode

Analog/digital/network synchronous output

Installation and Accessories

Matching unit: Each sensor is equipped with one unit, with a maximum distance of 25m from the sensor

Operating unit OP410: Panel installation, IP65， Used for local monitoring and debugging

Installation cabinet: wall mounted, floor standing MNS cabinet, dustproof and waterproof

Installation principle:

All measured forces must flow through the sensor

Install as close to the roller gap as possible

Avoid bending moment, lateral force, and torsion

Typical applications

Hot rolling mill: balanced load monitoring on operator side and drive side

Cold rolling mill: high-precision roll gap control

Pipe rolling mill/small rolling mill: small range precision measurement

All models: overload protection, roller eccentricity monitoring, bearing status monitoring

Key questions and answers

Question 1: What is the principle of Presductor magnetoelastic measurement for Millmate sensors? What are the core advantages compared to traditional force measurement?

Answer: Principle: There are two sets of 90 ° vertical coils inside the sensor, and there is no magnetic coupling when there is no load; After being subjected to force, the magnetic permeability of the steel changes, the magnetic flux is asymmetric, and the secondary coil generates a voltage proportional to the force. Advantages: No mechanical wear, extremely strong overload (300%/700%), multi measurement unit averaging, high output of 500mV anti-interference, extremely suitable for harsh rolling mill environments.

Question 2: What are the differences in installation position and applicable scenarios among circular, rectangular, and circular sensors?

answer:

Circular: Installed under the screw, it is the most versatile, cost-effective, and suitable for most rolling mills.

Rectangular: Installed under the bearing seat of the lower support roller, it does not affect the replacement of rollers and is suitable for space limited frames.

Circular: Installed between the compression nut and the frame, it provides the best protection and is suitable for ultra compact structures.

Question 3: What communication interfaces does Millmate Controller 400 support? What are the performance differences between Profibus and Ethernet?

Answer: Supports Ethernet (VIP), RS232, and Profibus DP (optional).

Ethernet: 10Mbit/s, 10 messages/second, automatic retransmission.

Profibus: up to 12Mbit/s, refreshing complete measurement data every 0.3ms, high-speed real-time control.