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VATECHVANTAGEControlSystem(VantageisaVAItrademark)WhatistheVantageSystem•TheVantagesystemisageneralpurposeindustrialcontrolsystemdevelopedbyVAI.Thismodelwasconfiguredforshapeandgaugecontrolonrollingmills.•Itisanaturalprogressivedevelopmentfromit’spredecessors–Davymap,System_Two,System21andVioneersystems–takingadvantageofthelatestPChardwareandoperatingsystemimprovements.•Sincemanyofthedevelopmentengineersarethesamepeoplethatworkedontheearliersystems,manyoftheshortcomingsexperiencedwiththosesystemshavebeenremoved.•Asthesystemisauniversalcontrolsystem(forhotmills,reversingmillsetc.)somefeatureswillnotbeapplicabletoallinstallations.Thus,someofthedescriptionswithinthegeneraldocumentationwillnotapplytothisinstallations.ItisnotVAI’spolicytotailorthedocumentationtospecificinstallations.•Inotherwordsifthefeaturedoesnotapplythenignoreit.ControlFeaturesVantage•AGC(GEFB)modes•ShapeControl•Load(Force)•Tension•Speed•+combinations•Bend•Steer•SpraysAdditionalVantagefeatures•PictorialOperatorandmaintenancediagnostictools.•Historydisplayofshapeandgaugetraces•RollLoadCylinderposition(gap)control.•Widows2000operatingsystem.•“Offtheshelf”hardware.•Fulldiscbaseddocumentation.•Individualcoildataloggingforpostrollingdiagnostics.TheOperatorsinterfacecomponents•FlatScreenMonitor,keyboard/andtrackerball/mouseattachedtoanetworkedPC.•TheMonitor,keyboardandswitcheshavebeenselectedtoberesilienttoindustrialgrimefromtheexpectednormalusage–(oilyfingersanddustshouldnotcauseproblems).•AndviaaProfibusnode•Pushbuttonswitchesforvarioussimplecontrolfunctionselection•Spinwheelmodules(digitalpotentiometers)foradjustmentsto“analoguethread/runreferences.•Theprimaryrootpageofthedisplayistermedthe“processpage”–displayingtheoperatingconditionsandstatusinformation.•Additionaldiagnosticanddataentrypagesareaccessedbycursorselectedpulldownmenus(ordirectkeyboardfunctionswitchesF1–F12).GaugehistoryTraceOperatorsProcesspageInstantaneousshape/spraydisplayShapehistoryTraceMillMimicPulldownmenuShapeTracedisplaysCurrentshapeAbove=tightBelow=looseActivespraylevelsGreen=autoBluemanualClickheretoincrease/decreasescaleShapehistoryBluetightRedLooseStartTimedtraverse“Now”GaugetraceClickheretoincrease/decreasetracescaleGEFBstatusGrey–notselectedYellow–selectedbutwaitingGreen-activeDigitalgaugeerrorvalueGaugeerrorbargraphHistorictraceTypicalPullDownmenuoptionsEnteredbyF12or“clickonmenu”EnteredbyF11or“clickonmenu”EnteredbyF2or“clickonmenu”TypicalSubdiagnosticpanelsClicktogetthispause•Ifyouwantmoredetailedexplanationsofthe“diagnostics”andadditionalpagesthentheyarefullyexplainedinthe•OperatorsUserGuideManual.•Storedonthesystemasatextdocument.•Naturallynotallpossiblefaultscanbeaccessedfromtheoperators’diagnosticscreens.MoredetailedVAI-SPYsareavailableontheSystemManagerandtheEngineersterminal.Ingeneralthefirstpointofinvestigationsshouldbebytheoperator.•E.G.ifthesystemrefusestoallowexitfromventtheremaybeasimplereason–sayhydraulicfailure–orsomemoremajorfaultsuchasaservovalvefailure.CriticalDataEntry•Inprinciplealldataentryiscriticalforvariousreasonsandwillhavesomeeffectonthesystemperformance.Enterwrongdata-thenthesystemwillrespondbymakingthewrongcalculationsandcorrections.•Entry&Exitgaugereferences.•Exitgaugeobviousbecausethatisthetargetfinaloutput.•Theratioentry/exitisusedtoadjustinternalresponsefactorsthatchangebetweenpassesanddifferentproducts.•Tension(stress)references–willhaveaneffectontherollingspeedandofflineshape.Bydefaultthespilloverlimitsandmaximum/minimumlimitsofstressaresetfromthisentry.•RunSpeed–variationsinrunningconditionsvarythethermalstabilityofthemillandtheofflineresults.Spilloverlimitsandmaximumlimitaresetwithreferencetothisdataentry.•Force–this“load”valuewilldeterminewhenthegaugegetstotargetandtheamountofoutoftoleranceproduct(scrap)foreachpass.•Stripwidth–shapecontrolneedstoknowhowwidethestripissoitcanignorezonesoutsideofitsmeasurementsystem.E.G.ifthesystembelievesthattheproductiswiderthatitisthentheoffstripzoneswillbetreatedasiftheywereloose.Other“Critical”DataEntry•Rolldiameters.•BothWorkrollandBack-uprolldiametersareusedtocalculatewherethepasslineshouldbe.•TheWorkrolldiameterisalsousedtoadjusttheconversionfromMillSpeed(metres/minute)tomillmotorrevolutionsperminute.•Rollidentitieshavenoeffectonperformancebutareusefulintrackinglongtermqualityissues.•Coilnumbers–notessentialdatabutareusefulfortracingbackcoilswhenqualityissuesarise.Asthesystemstoresdataonatimestampedbasisitisnotabsolutelyessentialbutdoesmakelifesimpler.•Alloy–fortheagcsystemthealloyisnotimportanthoweveritispassedtothegaugesystem.Itneedsthisdatatobecorrectsothatit’sinternalcompensationdatacanbeused.AGCControlModesGEFB•AGCmeans:-AutomaticGaugeControl.•GEFBmeans:-GaugeErrorFeedBack.•GEFBisachievedbyadjustingoneofthePRIMARYactuators(rollloadcylinders,EntryTension,Millspeed)inresponsetoa“deviationerror”fromagaugemeasurementunit.Ifthegaugeisundertarget(thin)thentheprimaryisreduced;Ifthegaugeisovertarget(thick)thentheprimaryisincreased.•Therearenohardandfastrulesthatdefineanexactthicknessthatanyparti