1. Technological Evolution in Metal Rolling
In an industry historically dominated by used cold rolling mill equipment with inherent precision limitations, our 350mm 4-High Cold Rolling Machine represents a generational leap. Designed as a complete Precision Metal Rolling System, this advanced mill integrates German control technology with Japanese mechanical engineering to achieve unprecedented tolerances (±0.001mm) across diverse materials - from ultra-thin battery foils to high-strength aerospace alloys. Unlike refurbished used cold rolling mill solutions, its 4-high configuration delivers 40% greater rigidity while reducing energy consumption by 25% through regenerative drives, establishing new benchmarks for precision manufacturing in electronics, automotive, and specialty metals sectors.
2. Core Mechanical Architecture
Figure 1: 4-High Mill Configuration Diagram
[Insert schematic showing work/backup roll interaction]
2.1 Roll Stack & Frame Design
Rolling Width: 350mm (motorized adjustment ±0.05mm)
Work Rolls:
Material: Hardened chromium steel (HRC 62)
Diameter: Ø85mm | Surface Roughness: Ra 0.05µm
Cooling: Internal high-velocity water jets
Backup Rolls:
Diameter: Ø250mm | Deflection absorption: 70%
Material: Forged 70Cr3NiMo steel
Frame Rigidity:
Deflection control: ≤0.003mm at 150-ton load
Column cross-section: 1,800cm²
2.2 Force & Width Control
Rolling Force: 50–150 tons (0.1-ton resolution)
Specific pressure: 2,200 N/mm² max
Hydraulic screw-down system: <0.2s response
Dynamic Width Adjustment:
Side guide positioning: 0.01mm steps
Width transition: 100→350mm in ≤30s
Laser edge detection: ±0.1mm tracking
3. Precision Control Systems
3.1 Thickness Management
Table: Tolerance Comparison vs. Conventional Mills
Measurement Systems:
X-ray thickness gauge: 0.1µm accuracy @30m/min
Laser profilometer: 800 data points/sec
AGC Implementation:
Hydraulic response: <0.2s
Deviation reduction: ±0.001mm (vs ±0.005mm without)
3.2 Automation & Intelligence
Control Architecture:
PLC: Siemens S7-1500 redundant system
AI Algorithms: 35% scrap reduction through roll force prediction
Tension Control:
Range: 5–50 kN (±1% stability)
Inertia compensation during acceleration/deceleration
Flatness Management:
Automated crown compensation
Output flatness: ≤1.5 I-units
4. Performance Validation
4.1 Material-Specific Capabilities
4.2 Operational Efficiency Metrics
Changeover Time: 5-minute thickness transitions (0.1→3.0mm)
Energy Recovery: 25% deceleration energy regeneration
Predictive Maintenance: 300-hour early warning on bearing wear
5. Industry-Specific Advantages
5.1 Electronics Manufacturing
Ultra-thin capability: 0.1mm copper foil with ≤0.3% elongation
Static control environment compatibility
EMI-shielded control cabinets
5.2 Automotive Tier 1 Suppliers
HSLA steel processing at 40m/min
Mirrored finish for decorative trim (Ra ≤0.15µm)
SIL 3 safety compliance for unmanned operation
6. Retrofit Solutions for Legacy Mills
This 4-High Cold Rolling Machine offers revolutionary modernization for used cold rolling mill installations:
Hybrid Control Integration: Retrofittable AGC packages compatible with 1980s+ mills
Mechanical Upgrades: Bolt-on rigidity enhancement kits
Digital Twin Simulation: Predicts performance gains before physical modifications
Legacy Interface Support: OPC-UA connectivity for existing SCADA
7. Sustainability & Maintenance
7.1 Environmental Leadership
Energy consumption: 0.28kWh/kg (industry avg: 0.45kWh/kg)
Heat recovery: 30kW waste heat capture system
Oil management: Zero-leak circulation with 5µm filtration
7.2 Smart Maintenance Systems
Vibration analysis: Online FFT monitoring of gear mesh frequencies
Oil condition sensors: Real-time viscosity/total acid number measurement
Augmented reality: Remote expert guidance via HoloLens interface
8. Technical Specifications Summary
Table: Performance Benchmarking
9. Competitive Positioning
Unlike conventional used cold rolling mill equipment, this integrated Precision Metal Rolling System delivers:
52% Higher OEE through reduced setup times and scrap rates
Material Savings worth $380,000 annually (based on 15,000t output)
Future-Proof Architecture with IIoT connectivity (MQTT/OPC UA)
10. Conclusion: Redefining Precision Rolling
This 350mm 4-High Mill transcends traditional Precision Metal Rolling System capabilities through its synergistic integration of mechanical excellence and digital intelligence. By delivering sub-micron tolerances across unprecedented material thickness ranges while offering seamless modernization paths for used cold rolling mill assets, it establishes new profitability paradigms for high-value metal production. The system's SIL 3 safety certification and 25% energy reduction make it the responsible choice for manufacturers targeting AS9100 or IATF 16949 compliance.
