Smart Technology limited

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Smart Technology Ltd.

PO Box 13272

Solihull, West Midlands,

England. B92 9EU


Telephone :

+44 (0)845 644 5059

Fax :

+44 (0)121 2756197

Email :

smart@smarttec.co.uk



Smart Technology limited





24 Channel Smart Hengtong/ EDT System


©Smart Technology


all rights reserved




Issue date

02 May 2011


Issued to







Specification Reference

Smart
-
10121
1
-
24
-
1.0



This Document

is private and confidential and is not to be issued to any third
party without the written permission of Smart Technology Limited.



24

Channel EDT System




Quotation No.Smart
-
10121
1
-
24
-
1.
0

2
nd

May 2011




Page
2

of 44

CONTENTS



Section

Description

Page

A

Technical Specifications

3

A1.0

Introduction

4

A1.1

Smart Technology

4

A1.2

System Requirements

5

A1.2.1

Roll Information

5

A1.2.2

Site Information

5

A1.3

General Description

6

A1.4

Basic Specifications

8

A1.5

Roll Surface Finish


9

A2.0

Description of the EDT System

1
1

A2.1

The Roll Rotation Unit

1
1

A2.2

Texturing Head

1
5

A2.2.1

Servo Modules

1
6

A2.2.2

Dielectric Delivery Manifold

1
7

A2.2.3

Barrel Edge Texturing

1
8

A2.3

Dielectric System

1
8

A2.4

Smart EDT Controller

20

A2.5

Power Cabinet

2
2

A2.6

A2.7

A2.7.1

A2.7.2

Fire Protection System

Consumable and spare parts

Consumable Requirements in Normal

Operation

Typical Spare Parts list for 2 Year Operation (
24

Channels)

2
6

27

27

28

A2.
8

Operation of the Smart EDT System


30

B

Commercial Issues

3
8

B1.0

Buyer’s Responsibilities

3
9

B2.0

Seller’s Performance Guarantee
Figures and Test / Acceptance Method

40

B2.1

Methodology

40

B2.2

Pre
-
shipment (shop) Tests

41

B2.3

Acceptance Tests at Customer Works

(Final Acceptance Tests)

41








Appendix 1
: List of EDT Equipment

4
3







24

Channel EDT System




Quotation No.Smart
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May 2011




Page
3

of 44


SECTION A


TECHNICAL SPECIFICATIONS





24

Channel EDT System




Quotation No.Smart
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Page
4

of 44

A1.0

Introduction



A1.1

Smart Technology


Smart Technology
produces a range of high performance specialist equipment,

as well as retrofitting new
control equipment. Smart manufactures
Electro
-
Discharge Texturing (EDT) Systems, Friction Stir Welding
mac
hines, and a wide range of
non
-
conventional
machine tools.
In 2008 Smart and Hengtong Machinery of
Anshan, China established a joint venture company to market the EDT equipment worldwide. First machine
was successfully sold and installed in Essar Indones
ia near to Jakarta in 2009.



Smart Technology Limited






All steel companies, world
-
wide,
currently accept Electro Discharge Texturing, EDT, as the preferred method for
texturing their rolls.


The Smart EDT system is designed to meet customer’s requirements. It is a cost
-
effective system, with the
following features.



Productivity:

Fast textu
ring times on all roll types



Repeatability:

Pre
-
set parameters for a required texture repeatable with
total consistency.



Reliability:

Proven in industry over many years.



Flexibility:

Can be configured according to customer’s requirements

In some
cases, it can be upgraded for future expansion.



Uniformity:

Maximum surface uniformity across the roll.















Smart Technology
also carries out research

and development
into

a
revolutionary new class of actuators based on
Smart Materials
.

These
Smart devices offer excellent dynamic characteristics and extremely high
resolution. They are particularly suited to precision machining and optical
positioning applications
.


Smart is also the world leader in manufacturing the electro
rheological

smart fluid.



24

Channel EDT System




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Page
5

of 44

A
1
.
2 System Requirements
.


A1.2.1

Roll Information


The type of rolls to be textured is given in the table below.














Please note

all dimensions are in millimetres (mm) :


A1.2.2

Site Information



The environmental data of the site will be considered when preparing final machine specification. All electrical
and mechanical assemblies will be designed and manufactured to ensure
compatibility.

Roll





Characteristics





Barrel Diameter

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24

Channel EDT System




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of 44

A1.3

General Description

Please note this quote is for one head / 12 Channel only


EDT

System supplied to
Essar

(
Indonesia
)

One (1) Texturing Head, with Twelve

(12
) Servos.


The Smart EDT system is based on the
T
raversing Texturing Head
assembly
. The system
has one (1)

Texturing
Head;

the

head assembly houses the
servo modules

which carry the electrodes
. Each servo m
odule
controls the movement
of
the

electrode
s
, using the advanced servo control

system developed by Smart. The
Texturing Head Assembly traverses (scans) the full length of the roll, thereby ensuring a consistent and
uniformed surface finish. With this unique scanning feature, the Smart EDT system can easily texture varying
lengths and diameter of rolls.



The indi
vidual servo control allows the system to also texture crowned and tapered rolls, as well as being able
to cope with roll eccentricity. Another feature of the individual servo control and scanning process of the
Texturing Head Assembly allows the Smart EDT

system to perform
barrel edge texturing
. As each electrode
(servo) reaches the end of the barrel, it is retracted and locked in position, this continues for each servo in the
column, and for the number of columns selected by the operator. As the next pass

begins, the operation works
in reverse


as each electrode (servo) comes back onto the barrel, it is unlocked and the

electrode (servo)
begins to texture again. This procedure ensures a uniformed surface texture from end to end of the barrel.




24

Channel EDT System




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The

Textur
ing Head Assembly is supplied with dielectric at a rate of two hundred (200) litres p
er minute. The
Smart EDT system

use
s

a special
flushing manifold
, which ensures the dielectric oil is supplied to the tip of
the electrode. The manifold also ensures there

is a consistent level of dielectric around the electrode tip during
the texturing process. The dielectric oil is filtered, cooled and recirculated using an advanced filter system. The
efficiency of the filtration system helps to ensure that there is minim
al degradation of the dielectric oil as each
roll is textured, which ensures consistency of the roll surface.





One (1)

fume extraction

unit is supplied with the system. This unit

ensure
s

the air quality
. The Smart EDT system is among the safest
availab
le, the work chamber is total enclosed during the texturing
process.


The Smart control console provides full control of the texturing process.
A wide choice of surface finishes from 0.
5
µm to
6
.0µm Ra is

available
.
The Smart power cabinets supply the
special electric energy waveform
for efficient texturing.



















Another example of an EDT system supplied by Smart and installed in S
umi
tomo Metal Industries in Kashima,
Japan. The system is 100 channels, fully automated.












24

Channel EDT System




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A1.4


Basic Specifications
















Equipment Type

24

Channel
Low Cost

EDT
system
.



Roll Rotation Unit.

D
escribed in section A2.1

Maximum between centres

55
00 mm

Roll Length

7
00 to 50
00 mm

Roll Diameter

300 to
7
00 mm

Maximum Roll weight

8

Tonnes



Texturing Head Assembly

Described in section A2.2

Number of head assemblies

One (1)

Number of
channels

per head

Twenty four

(
24
)





Controller

D
escribed in section A2.3

Roll Rotation Unit

Siemens 840D



Power Cabinet

D
escribed in section A2.4

Total number of channels

Twenty four

(
24
)

Texturing modes

Pulse mode

Machining Pulse Power / channel

30 Amps

Open Circuit Machine voltage

100 Volts

Initiation Pulse Power / channel

1 Amp

Open Circuit Initiation voltage

300 Volts

Polarity

Selectable
Positive or Negative





Dielectric System

D
escribed in section A2.5

Type of Dielectric

ESSO Mentor 28 or equivalent

Capacity of System

Approximately
5
000 Litres

Type of Filter

Surface Filter







24

Channel EDT System




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Fire Protection System

D
escribed in section A2.6

Type of system

Fully Automatic

Gas Used

High Pressure
CO2

Type of Detector

Infra Red and Temperature Probes

Number of Infra Red

Two (2)

Number of Temperature Probes

Two (2)

Number of Fume Extraction Units

One

(1)



Roll Surface Finish

D
escribed in
section A1.5

Ra attainable

0.
5

to
6

µm Ra


Peak Count attainable

35

to 250

PC

max


Utility Consumption Data


1)
Electrical Power

9
0

KVA

TBA



50

Hz

(
±
3%)




2)
Compressed Air

60 litres / min
and

6 Bar

Dew point at nominal pressure





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<5m术m2

Du獴⁰ 牴楣汥⁤楡meter


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μ
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A
1
.5
Roll Surface Finish


As a guide, Figure shows the relationship between the surface roughness Ra in

m and the Peak Count in Peaks
per
cm
.


Figure
-

Typical relationship between Ra and Peak Counts




The peak count results in the graph above are measured with a threshold from C1=+0.5um, C2=
-

0.5um.




20
40
60
80
100
120
140
160
180
200
0
1
2
3
4
5
6
7
Peak Coun PC Peak / cm

Surface Roufgness Ra μm




24

Channel EDT System




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24

Channel EDT System




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A2.0 Description of the EDT System


The EDT
system

consists of the following assemblies




The EDT Roll Rotation Unit



The Texturing Head



The Dielectric Unit



The EDT Controller



The EDT Power Cabinets, and



The Fire Protection System


A2. 1
The
Roll Rotation Unit


The Roll Rotation
Unit

consists of:
-





Headstock


1.

Powered by the CNC manufactures AC spindle motor
producing a 30 HP single speed range headstock. The
spindle speed is set via the CNC controller an
d is
selectable between 1.5 to 2
0 rpm.

2.

The Headstock is fitted with a catch plate and drive dogs
to assist with the roll loading / unloading procedure.

3.

Number 6 Morse taper centre is fitted to the headstock to
aid with the roll loading / unloading procedure.

4.

A Jog station is available, to allow easy control of the
headstock during loading and unloadi
ng the roll.




Saddle


1.

The texturing head assembly is mounted on
saddle
.

2.

The saddle is driven by a CNC manufacturer digital
servomotor, via a precision ballscrew. The saddle
feedrate is fully selectable,
from the CNC controller.












Steadies



24

Channel EDT System




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1.

Two
manually adjusted steadies are fitted and run on the cast
iron bedways..

2.

The steadies are manually clamped to the bedways, with
keep plate. The steadies are manually positioned along the
bedways using a rack and pinion drive
.




Tailstock

1.

Heavy
-
duty tailst
ock, fitted with quill and rotating number 6 Morse
taper centre to aid with the roll loading / unloading procedure.

2.

The quill is hydraulically controlled. It is controlled by push
buttons on the control pendent.

3.

The tailstock is manually positioned along the bed via a rack and
pinion drive.

4.

The tailstock is clamped to the bedways with hydraulic clamps.




Hydraulic Pack


1.

The Hydraulic Pack provides all necessary hydraulic fluid and control for the tailstock
opera
tion.

2.

The Hydraulic Pack has a number of sensors

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Machine Guarding

1

W
ork chamber guarding

is manually opened and closed
.

2

Interlocks on headstock,
tailstock, and work chamber doors to ensure they are closed during
the texturing process.



Figure 2



General arrangement of the

EDT System

(For example)



24

Channel EDT System




Quotation No.Smart
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General arrangement of
the

EDT System

(For example)



24

Channel EDT System




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The foundation for the EDT machine, at a minimum, should be put on at least a

610mm deep concrete slab.
Ideally if there is ambient vibration, the EDT machine should be put on an isolation base (similar to the rol
l
grinders). The EDT machine is very susceptible to 'outside' vibration. The

vibration will cause the texturing
times to increase and to prevent the EDT machine from achieving low
surface roughness.














Figure 4



General arrangement of the

EDT System

(For example)



24

Channel EDT System




Quotation No.Smart
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of 44

A2.2

Texturing Head


Please N
ote

machine quoted here is a single texturing head with
twenty four

(
24
)

channels
.


The texturing head consists of




A Housing



positioning slides



Servo modules



24

Electrodes



Dielectric delivery system


Texturing Head Assembly


The
Texturing Head Assembly

is a steel unit, which contains and protects the
Positioning Slides

during their
operation
.


Positioning Slides


The Positioning Slide houses the Servo module. The Positioning Slides are housed in the Texturing Head
Assembly.
The Texturing Head Assembly c
an house
up to
five (5) Positioning Slides.


Each Slide locates six (6
)

servo modules and positions them relative to the roll. The stroke of the positioning
slides allow for different roll diameters to be textured. Also attached to the positioning slide is a dielectric
manifold, which provides the dielectric supply during the

texturing process. All the Position slides point to the
centre of the roll.


The positioning slides are driven independently under CNC control. Before the texturing process the slides are
driven towards the roll
.

Once in position each individual servo the
n is activated and these
servo
drive the
electrodes forward to start sparking on to the roll surface.






















Photograph shows an EDT machine Texturing head with 12 servos only


24

Channel EDT System




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A2.2.1 Servo modules


Servo Modules


The servo module is a
modular design allowing it to be removed easily and quickly from the Texturing Head
assembly


regardless of its position, within the head assembly.




Each servo can be extended or retract, to allow the operator to change the electrodes quickly and easil
y.


Electrode


Copper electrodes are used. Each electrode is fed with dielectric in its centre. The electrode can be easily
changed.







Copper Specification
99.90
% Cu
00.01
% Sn
00.05
% P
00.03
% Fe
00.05
% As
00.01
% Ni
00.001
% Bi
A
CONFIDENTIAL - CRAWFORD-SWIFT LTD.
A
COPYRIGHT - CRAWFORD LTD. c
HALIFAX - ENGLAND
SECTION A-A
SMART TECHNOLOGY GROUP


24

Channel EDT System




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A2.2.2 Dielectric delivery system




The Smart

EDT system uses a Dielectric Delivery Manifold to
ensure there is a continuous pool of dielectric arou
nd each
electrode.
Each manifold supplies the
dielectric for one row of
electrodes. Each electrode is supplied with its own dielectric
fluid via eight (8) holes surrounding the electrode. A brush
material is also used to hold the dielectric around each
electrode
.


Manifold Material

is
made from a PTFE

material
.





This figure shows the electrodes advancing through the manifold.








This figure shows the manifold and the electrodes during
texturing. The bristles of the brush keep the electrode tip
fully submerged in oil ensuring safe
operation.




Dielectric Control



Dielectric oil is supplied to the texturing gap via the Dielectric Delivery Manifolds, and the centre flush dielectric
through the centre of the electrode.



1.

Within each Texturing Head Assembly are
Twenty four

(
24
)

electrically operated solenoid valves, which are
used to control the centre flush dielectric. All the solenoid
-
operated valves are supplied with dielectric from
a common manifold. This assures that all the electrodes in the Texturing Head Assembly are oper
ating at
the same dielectric fluid pressure. Each solenoid valve can be individually
operated;

this allows any single
servo module to be removed from service with the dielectric fluid turned off without affecting the operation
of the servo modules remainin
g in service.





24

Channel EDT System




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2.

The Smart EDT system uses a Dielectric Delivery Manifold to ensure there is a continuous pool of dielectric
arou
nd each electrode.
Each manifold supplies the dielectric for one row of electrodes. Each electrode is
supplied with its own diele
ctric fluid via eight (8) holes surrounding the electrode. A brush material is also
used to hold the dielectric around each electrode.


3.

The dielectric fluid flow, temperature and pressure are monitored by sensors mounted on the Texturing
Head Assembly and

relayed back to the CNC controller. If any of the sensors cause a fault condition,
texturing stops and a message is displays on the CNC controller.


A2.2.3 Barrel Edge Texturing




As the next pass begins, the operation works in reverse


as each electrode (servo) comes back onto the
barrel, it is un
locked and the electrode

begins to texture again
. This procedure ensures a uniformed surface
texture from end to end of the barrel.




A2
.
3 Dielectric System




The Dielectric filter system comprises of two (2)
tanks


dirty tank which holds the dielectric
which has not been filtered, and the clean tank
which holds the dielectric which has been
filtered.


The dielectric i
s returned fro
m the Roll Rotation
Unit via a Sump Pump
. The dirty dielectric is
pumped out of the dirty tank, through the filter
units
, into the clean tank.


An oil
temperature controller unit
is utilised to
cool

/ heat

the dielectric in the clean tank. P
umps
on the clean tank, pump the clean dielectric back
to the Texturing Head Assembly
.






Due to the individual servo control and scanning
process of the Texturing Head Assembly. The Smart
EDT system can perform barrel edge texturing.


As each electrode

reaches the end of the barrel, it is
retracted 5mm and lock in position, this continues for

each servo in the column, and for the number of
columns selected by the operator.




24

Channel EDT System




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Filter
Units


1.

There are two (2) filter units



one unit will be used for operation, while the second unit is a
spare. The units are switched over easily by a Ball
valve.


2.

Each
Filter
Unit contains nine (9) filter elements
.

3.

Each filter group supply approximately
20
0

litres of filtered dielectric oil to the clean tank.




Pump information


There
is

one

(
1
) filter pump

on the dirty dielectric
tank, which

pump the dirty
dielectric

to the
respective
F
ilter
Unit
.


There are three (3)
pumps mounted on the clean tank


one

pump supply
’s

the manifold
dielectric to the
T
exturing
H
ead

Assembly
, and the other pump supply the centre flush dielectric
.

The third pump

is used to pump dielectric oil out of the clean tank to the
oil temperature
controller
.


There is one (1) pump

(Sump Pump)

mounted on the EDT Machine which

pump the dirty
dielectric back from the EDT Machine to the Dirty Dielectric Tank.




All the pumps
are monitored and controlled via the CNC Controller.




Oil Temperature Controller “OTC”


Dielectric oil is pumped from the clean tank to the dielectric oil
OTC
. A thermostat mounted in
the clean dielectric tank controls dielectric oil
OTC and to ensure
that the dielectric oil
temperature is maintained within a preset range
.




Sensors


There are level sensors in
the D
irty
T
ank
, the Clean T
ank

and the Sump Tank
. The level sensors
indicate a low level of dielectric. If any of the level sensors are activated

it will cause an
emergency condition, causing the EDT texturing to stop and the Dielectric filter system to stop.
These sensors are for safety precautions to prevent machining with an inadequate supply of
dielectric. An appropriate message is displayed on

the CNC control system informing the
operator of the fault.




Dielectric Oil


The dielectric oil recommended by Smart Technology is a CLC EDM 3001 Lite, which is a
synthetic oil with high flash point. Refer to A2.
5.2

f
or the Recommended dielectric oil
data
sheet. However any suitable EDM dielectric oil will be acceptable. For example:

ESSO Mentor 28

SHELL EDM Fluid 130
/110

EXXON Lector 45




Control


The dielectric system is controlled through the CNC control.





Spark Enhancement
Additive “SEA”


Texturing using
very

pure dielectric oil is less efficient. Clean dielectric oil after being filtered will
not
produce effective sparks especially at the outset of the texturing process. Smart recommends adding
small amount of additives to clean dielect
ric oil to enhance the texturing efficiency and to help produce
uniform texture on the roll surface. This operation is not the same as continuously adding large quantities
of graphite powder by one competitor who are using many electrodes on one servo. T
otal amount of SEA


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in the system is around 5 Kgm, and only 250 gms are added when more dielectric oil (200 litre) is added
to top up the dielectric oil level.



Dielectric Filter Unit


A Filter Unit consists of nine (9)

individual filter stick
s
, placed on a central guide mandrel. The length and
number of filter sticks placed in
the Filter Unit

determi
ne the total filtered flow of the Filter Unit
.





A very high consistency of filtration is achieved around
10

Micron.



A2.
4

Smart EDT

Controller


The Smart EDT control structure is based around a high
performance industrial control system



Siemens 840D
CNC
.


The Local Machine Control (LMC), which provides the
Smart Operator Screens, Manual Control, and the
Maintenance screens. This wo
uld be mounted in close
proximity to the Smart EDT system.


The Local Machine Control (LMC)


The LMC is located near to the Smart EDT System, it is
used to control all the functions of the EDT machine.
From
this point the Operator can view the status of th
e EDT
process.


Mounted at the top of the LMC are the EDT Analogue
Meters


these display the status of each of the EDT
channels during texturing.




24

Channel EDT System




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The Operator Panel provides all the required information for the Operator to control and monitor the EDT
process.
The Operator Panel displays the standard Siemens screens as well as the custom screens which Smart
have produced


Smart EDT screens.


Mounted

below the Operator Panel is the Machine Control Panel (MCP), this provides the standard Siemens
pushbuttons, Custom pushbuttons and Jog pushbuttons.



















The Remote IO (input / output) stations are connected to the LMC via a Profibus
network.


Using Remote IO Stations, provides a modular design to the system, it eliminates large amounts of
interconnection wiring, and allows the control structure to be expanded at a later date. As a mater of course,
Smart provides 20% housing and termin
als for future expansion.


The Remote IO stations are located on the Roll Rotation Unit, Dielectric System,

and in each Power Cabinet
.



The Servo axis and spindle drives, of the Roll Rotation Unit, are connected to
the LMC via a second digital network.
The Servo axis and spindle drives
provide control and monitoring of the axis and spindle motors located on the
Roll Rotation Unit. The Servo drives, spindle drive and the control algorithm
are based on the either the Siemens or Fanuc digital drive system.






Also located in the
LMC

is the Fire Control Panel. This is a dedicated system designed to provide monitoring of
field wiring, field sensors (located in the EDT work chamber and the Dielectric tanks) and the control of the C02
cylinders. The LMC provid
es secondary monitoring of the Fire Control Panel.


From the LMC the following functions are available :
-


(a)

Manual Control


The LMC allows the Operator / Maintenance Personnel to manually move the sub
-
assemblies of the Roll Rotation Unit, to extend and ret
ract each electrode, and to jog each of the
controlled
axes
.


(b)

Maintenance Diagnostics


The LMC also provides tools to interrogate the Remote IO stations, to force
outputs on / off, and to verify the performance of the servo axis.



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Channel EDT System




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(c)

The Smart Operator
Screens


From the LMC the Smart EDT System can be operated using the Smart
Operator Screens
.



A2.
5

Power Cabinet


The Power Cabinet houses the electrical and electronic components required to generate the texturing
waveform. Each Power Cabinet controls the operation of six (6)
servos
. The Power cabinet has the following
features:
-




Enclosure



1.

Manufactured from 2mm
Steel plate, the enclosure measures
2100mm (H) by 1200mm (W) by
600mm

(D). IP rating IP55 (NEMA
12)


2.

Double door access, allows ample access to the interior of the
enclosure. All electrical components are mounted on 3mm
galvanised steel mounting plate. All

internal plates and the
enclosure are earthed.


3.

All electronic racks are mounted in a swing frame assembly


this
allows
easy access to the rear of the racks and to all the electrical
components.


4.

The enclosure is fitted with two internal fluorescent lights, which
are
operated when the enclosure doors are opened.


5.

All cable access is through the bottom of the enclosure.


6.


Air flow inside the cabinet is provided by the two(2) door fans, which
suck
air into the enclosure. There are two(2) fan trays mounted in the swing
frame, ensuring adequate air flow for the electronic racks, and four (4) fans
mounted on the current limiting resistor box to ensure adequate air flow
within the current limiting resis
tors. The warm air is vented out of the top of
the enclosure.


7.

Each cabinet has it own isolator, to disconnect it from the three
-
phase
supply. There are three (3) phase warning lights fitted to the front door of the
enclosure.


8.

There are six (6) voltmeter
s and six (6) ammeters fitted to the front door
of the enclosure to indicate the machining performance of each of the

six
channels.








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Machining Data


1.

The Power Cabinet produces two (2) waveforms, when texturing a roll

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an搠dhe⁍=ch
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the⁤楥汥ct物挠rn搠獴a扩汩獥猠the⁧=瀬⁷h楬i⁴he⁍=ch楮e=灵汳攠楳⁵獥搠d漠灲ov楤i⁴he⁲=煵楲敤=
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mul獥
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=


Machining Waveform.



Machining open circuit voltage is 100 Volts dc.



Machining power is selectable from 1 Amp. to 30 Amps



Machining waveform is selectable from (minimum) 3
µSec. On ; 3 µSec Off ; to (maximum)
999 µSec On; 999 µSec. Off.


3.

Initiation

Waveform



Initiation pulse open circuit voltage is 300 Volts dc



Initiation power is fixed at 1 Amp.



Initiation waveform is fixed at 3
µSec On.



Figure


Initiation Pulse and Machine Pulse






















The Initiation Pulse is required for high quality texturing, preferable at low roughness below 2 Ra. The Initiation
Pulse breaks down the dielectric, which ensures the machine pulse power is only used for the texturing process.
The Initiation Pulse improve
s the efficiency and stability of the sparking process, and finally the Initiation Pulse
increases the spark gap.


Compared with conventional spark erosion systems, the Initiation Pulse will increase the spark gap between 3
and 5 times as much.







The ‘machine pulse’ provides a pulse of power to the
electrode.

The pulse duration is selectable from 3
µSec On
and 3µSec Off to 999µSec On to 999µSec Off.


The Machining power is selectable from 1 to 30 Amps.


The Initiation Pulse power is fixed at 1 Amp, and the
duration of the pulse is fixed at 3µSec at the
beginning of
each machine pulse.



The Initiation Pulse is superimposed on the machine pulse.
This waveform can be seen on each electrode.





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Ser
vo Control


The Power Cabinet controls six (6) servo motors (six electrodes), the following schematic describes how the
Smart EDT Servo system ensures efficient machining.























1

The EDT Waveform is monitored at the electrode tip. This ensures the servo system
has a true representation of the sparking efficiency at the spark gap.


2

The spark gap waveform (100V in
amplitude) is scaled down to provide a 0 to
10Vsignal of the spark gap.


3

The ‘Sample and Hold’ circuitry, allows the Servo System to monitor the ‘on time’ of
the EDT waveform. The sampling pulse has a 2uS leading edge delay, to avoid
unwanted signals su
ch as the Initiation Pulse.



4

After further filtering and opto
-
isolation of the Spark Gap Voltage (SGV), Smart has a
0 to 10V dc signal, which is a representation of the Spark Gap at that given electrode.




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Channel EDT System




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5

The Spark Gap Voltage (SGV
)

enters the servo board.


6

The Smart Servo Card contains circuitry to compare the SGV signal with a predefined
voltage (short circuit voltage). If the SGV signal falls below this
voltage, the servo will
retract at a fast rate.


7

The Digital to Analogue Converter (DAC) produces the ‘Threshold’ voltage. The
‘Threshold’ defines the spark gap voltage the servo system must sustain at the
electrode tip.

The ‘Threshold’ voltage is subtr
acted from the SGV signal.


8

A digital potentiometer is used to alter the speed of the servo system

(Gain)
.


9

For rapid movement of the servo, two analogue switches are used. This movement is
used to extend and retract the servo during electrode
changing.


10

The Servo drive signal is now used to command the servo amp, and in turn to control
the servomotor.



Please Note

: The signals


Threshold and Gain, are controlled by the Smart Control system and are set
automatically.




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Channel EDT System




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PLC & Controller C
ards


The PLC IO modules and the Smart Controllers cards have been designed to be installed / removed without the
need of any special tools.


Each output is fused, and all wiring is terminated onto screw terminals.


Remote Control and Monitoring


The Smart

EDT controller is fitted with a remote control module which will enable Smart
’s

engineers to monitor
the EDT operation and download any software upgrade. This feature will require connecting the EDT controller
to the Internet
network on site
.

(Please not
e that a static IP address needs to be allocated to the controller)


Motors


All spindle and servo motor
s

will be supplied by the CNC manufacturer. These are AC motors designed and built
for minimum maintenance and optimum performance. Refer to Siemens literature for further information.


All auxiliary motor are tropicalised AC squirrel cage motor. The Motors

supplied will be standard products
supplied by a well known manufacture.



A2.
6
Fire Protection System



Mounted next to the Smart EDT Controller is the Fire Control
Panel


allowing the Operator to view the status of the Fire
System at all times.


The
system consists of a fire control panel, 2 infra red (IR)
sensors, temperature sensors

(optional)
, Manual Release
buttons and carbon dioxide extinguishant stored in cylinders.
The system is designed in accordance with BS 5306, part 4
(and equivalent standa
rds) to protect the EDT work chamber,
Electric room, and the Dielectric Filter System.




From this unit the operator will see the complete status of the Fire Detection System, there are a number of
high visibility LED’s which indicate Discharge Imminent Z
one 1, Discharge Zone 1, Discharge Imminent Zone 2
and Discharge Zone 2. A key switch is also on the panel, which will allow the operator to switch the system
between modes. The modes are Automatic and Manual, Manual only and Disable. The system will, for

normal
operation, be in Automatic and Manual mode, however when the doors of the work chamber are open the Fire
system automatically will go into Manual only mode. Also on the unit are two (2) Manual Release switches, one
for zone 1 and the other for zone

2.










The Fume extraction system comprises of one (1
)
Filter unit, which is

mounted at one

end of the EDT
work chamber.


The suction pipe goes from the unit through the Cable
Chain to the Texturing Head Assembly. This ensures
the suction is above the source of the fumes.


The

unit has a throughput of 1200 c.f.m. and are
driven by a
three (3)
phase

motor.



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2.
7
:

Consumable and spare parts


2.
7
.1 Consumable Requirements
in Normal

Operation



Consumable Material

Quantity In
System

Typical Consumption per roll
replacement/top up frequency

Electrodes

24

Typically
8

rolls per set of electrodes
-

This figure varies dependent upon target
Ra

Dielectric Oil

5
000 litres

Dielectric is never changed but topped up
due to losses through

spillage,
evaporation

etc. One oil barrel (200
litres) per 200 rolls i.e. 1 litre per roll.

Spark
Enhancement

Additive

5 Kgm

Add 250 gm per 100 rolls.

Filter Elements

18

Replace every
4

month

Steady lubrication oil

-

½ litre per roll

Hydraulic Oil

100 Litre

1 Litre every

3 month if required.
Recommend to replace every 3 years.

General grease

-

Grease as instructed. Typical amount to
be consumed is 1 Kgm every 6 mo
n
th.

Lubrication Oil for Headstock

50 Litres

1 Litre every 3 month if requited.
Recommend to replace every
3 years.




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Channel EDT System




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of 44

2.
7.
2
:
Typical Spare parts list for 2 year operation (
24

Channel Option)


Ref No

Smart Part No

Qty

Description

1.0 Headstock Lubrication System




1

STL_400_501_011

1

Gear Pump with motor


2

STL_400_501_012

1

3/4 Inline suction filter

2.0
Headstock Assy




1

STL
-
400
-
501
-
010

1

DRIVE BELT
-

/ 12 PL 1715


2

STL
-
400
-
501
-
003

2

Oil Seal


3

STL
-
400
-
501
-
004

1

Lock Nut

3.0 Z Axis Drive Assy




1

STL
-
600
-
503
-
007

1

Drive belt


2

E1S1

1

3 Pin Limit Switch


3

STL
-
600
-
503
-
002

4

Oil Seal

4.0
Steady Assy




1

STL
-
700
-
001
-
009

2

Oilite Bush

5.0 Tailstock Assy




1

STL_500_501_005/kit

1

Clamp cylinder Repair kit


2

STL_500_501_006

2

Circlip 65mm


3

STL_500_503_001

1

Flexible hydraulic hose
-

Quill Lock


4

STL_500_503_002

1

Flexible
hydraulic hose
-

Tailstock retract Feed


5

STL_500_503_003

1

Flexible hydraulic hose
-

Tailstock retract Return


6

STL_500_503_004

1

Flexible hydraulic hose
-

Tailstock clamp

6.0 Texturing Head Assembly




1

STL_900_001
-
007

2

Servo Module


2

STL_900_001_008

2

Servo Motor


4

STL_900_001
-
015

2

Manifold Brush Strip


5

STL_900_001
-
025

2

Solenoid valve

+Coil


6

M3S15

2

Flow Switch


7

STL_900_010_089

2

Insulation Washer (Tufnol)


8

STL_900_010_ 090

2

Insulation Disk (Tufnol)


9

STL_900_010_091

2

Insulation Bush (Tufnol)


10

STL_900_010_
088/095

1

Electrode Back Plate/ Tube Assy


11

STL_900_010_096

2

Seal Housing (Tufnol)


12

STL_900_010_097

2

Guide Bush (Tufnol)


13

STL_900_010_099

2

Insulation Bush (Tufnol)


14

STL_900_020_001

12

O Ring
Dia 9 x 1.6


15

STL_900_020_002

12

O Ring Dia 15.1 x 1.6


16

STL_900_020_003

12

O Ring Dia 13.6 x 2.4


17

STL_900_020_004

12

O Ring Dia 27.1 x 1.6


18

STL_900_020_005

24

O Ring Dia 13.1 x 16


19

STL_900_020_006

24

O Ring Dia 15.6 x 2.4


20

STL_900_020_007

12

O Ring Dia 10.1 x 1.6


7.0 Dielectric System




2

STL_504_001

2

Solenoid valve+Coil



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7

M3S11
-
12

1

Adjustable float switch 1"bsp. 1000mm tube length

8.0 Guards Assy




1

STL
-
200
-
506
-
008

8

External circlip

9.0 Fire Detection / Fume
Extraction




1

STL_900_030_002

1

Fume Extraction Flex Hose


2

STL_900_030_003

1

Hose clip


3

H3S1/Glass

8

Break glass

10.0 Printed Circuit Boards




1

Rack + SM003
-
01

1

Power Rack


2

SM002
-
01

2

12V PSU


3

SM001
-
01

4
0

Power Card


4

SM004
-
01

4

Servo Card


5

SM005
-
01

4

CPU Card


6

SM002
-
01

4

5V, +/
-
15V PSU


7

CxAMP1
-

2

2

Servo Amplifier

11.0 Electrical




1

A8V1, A9V1
-

2

1

Siemens 24V @ 10Amps


2

E5V1

1

Siemens 24V @ 5 Amps


3

E2S1
-
2

1

18mm Diameter Actuator


4

E2S1
-
2

1

Double Pole
Contact Block


5

E2S1

1

Red Lens


6

E2S1

1

Midget Groove LED
-

RED


7

E2S2

1

Green Lens


8

E2S2

1

Midget Groove LED
-

GREEN


9

E1
-
STOP

1

Pilz Safety Relay


10

E2KA1
-
2
-
3

2

11 Pin Octal Relay


11

E2KA1
-
2
-
3

2

11 Pin Relay Base


12

PxKAx

10

Finger
Relay


13

A2F1
-
2
-
3

3

Semiconductor Fuse


14

A2KM2

1

3 Pole 80Amp Contactor


15

A2KM2

1

Aux. Contactor


16

A2KM2

1

Varistor


17

E3KM2

1

4 Pole 20 Amp Contactor


18

A3DAN1
-
2
-
3
-
4
-
5
-
6

2

Heatsink Assembly (Neg)


19

A3DAP1
-
2
-
3
-
4
-
5
-
6

2

Heatsink Assembly
(Pos)


20

A3C1
-
2
-
3
-
4
-
5
-
6

2

4700uF 250V Capacitor


21

A3R1
-
2
-
3
-
4
-
5
-
6

2

47R 25W Resistor


22

A3KM1
-
2
-
3
-
4
-
5
-
6

2

40A 3 Pole Contactor


23

A3KM1
-
2
-
3
-
4
-
5
-
6

2

Varistor


24

A5KM1

1

32A 3 Pole Contactor


25

A5BR1
-
2
-
3
-
4
-
5
-
6

2

35A Bridge Rectifier


26

A5C1
-
2
-
3
-
4
-
5
-
6

2

4,700uF 100V Capacitor


27

MxIPx

1

16 Point 24V Digital Input Unit


28

PxOPx

1

16 Point 24V Digital Output Unit

We recommend taking a standard Siemens service contract to ensure quick replacement of any faulty
Siemens parts.


24

Channel EDT System




Quotation No.Smart
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Page
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A2.
8

Operation of the Smart EDT System:


For
information of how to operate the EDT machine please refer to the
Smart Operator Manual
. The following section shows the Smart EDT screens which
are installed on the Siemens 840D CNC.


The Machine Status screen, provides the Operator with a central point to monitor / operator the EDT process.


Please Note :

You must be
in the ‘Machine Status Screen’ to download the EDT program to the CNC.





























EDT Status Window


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=
=
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扥⁰牯捥獳s搮
=
=
Screen Status


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wh楣h=獣牥en=he⁩猠楮Ⱐ
and which ‘Data’ file is
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the⁃乃⁣潮nect楯n.
=
Position Window


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a楳iance⁴漠d漠on搠dhe=
act楶e⁦ee摲dte.
=
=
Please Note

: the Row
positions can only be
seen in this screen.

Horizontal Softkeys


=
=
䅬汯A⁴he⁏灥牡t潲⁴漠
nav楧ate⁴h牯r杨⁴he⁅aq=卣牥en献s
=
=
Headstock Status


=
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䡥a摳d潣k=印敥搠d卥p…=
䅣瑵A氩Ⱐlhe⁳=atu猠潦⁴he=
䡥a摳d潣k⁡n搠dhe=
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the⁈=a摳d潣k.
=
=
Vertical Softkeys


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楮c牥ment爠摥c牥ment=
theum扥爠rf⁰=獳s猠
汥ft⁴漠摯o
=
Program Data


=
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w楮摯d⁳=潷猠she⁒潬氠
汩l楴猬⁴桥um扥爠潦=
ma獳⁳st⁡n搠dheum扥爠
潦⁰=獳s猠汥ft⁴漠摯⸠qhe=
ty灥=⁅aq⁃yc汥⁴he=
佰e牡t潲⁩猠捵牲rntly=
牵rnin朮
=
Message Window


=
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c潮veye獳s来猠s漠ohe=
佰e牡t潲o
=


24

Channel EDT System




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31

of 44


Parameters Screen


By pressing the ‘Parameters’ Softkey, the Operator can navigate to the
Parameter Screen


the Operator can set / view some of the EDT variables.































Horizontal Softkeys


=
=
=
䅬汯A猠she⁏灥牡t潲⁴漠
nav楧ite⁢=ck⁴漠ohe=
‘Machine Status Screen’
潲⁴漠瑨o瑨=爠rc牥ens
=
Vertical

Softkeys


=
=
=
䅬汯A猠she⁏灥牡t潲⁴漠
i潡搠潲⁓dve⁅aq=aata=
f楬i猬⁥楴he爠r漠ohe潣a氠
ha牤⁤物癥爠r漠o=r卂p
獴楣k⸠
=
Access Level


=
=
=
r獩s朠ghe⁋=y⁳=楴chn=
the⁍=chi
ne⁃潮瑲潬o
mane氬⁴桥⁏灥牡t潲⁣慮o
a汴e爠rhe⁁捣e獳sieve氠lf=
the⁳潦twa牥⸠qhe牥⁡牥=
f潵爠汥ve汳›
-
=
Operator,

Supervisor
,
Supervisor+
, and
Engineer
.


Roll Diameter


=
=
=
qh楳⁩猠sn⁡牥a⁴漠o楥w =
e摩d⁴he⁲潬氠摩=mete爮
=


24

Channel EDT System




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The

Parameter Table
, allows the Operator to view and modify the
EDT

Parameters. The Parameters are described further in Cycle Desc
ription.

Using the
softkeys the Operator can navigate to the other EDT Screens.


Access Level


The
EDT

Software can be protected to restrict the amount of ‘editing’ the Operator can do. Using the key switch on the
Machine Control Panel, the Access Level c
an be altered.

There are four levels :
-


(a)

Operator



restricts the Operator’s ability to edit the process variables. The Operator can Load the data file
from the harddisk of the CNC, but is unable to edit the fields.

(b)

Supervisor



Allows the Operator to Loa
d and Save the data file to / from the hard disk of the CNC. The
Operator can also edit the majority of the process variables.

(c)

Supervisor+

-

Allows the Operator to Load and Save the data file to / from the hard disk of the CNC. The
Operator can also edit all of the process variables.

(d)

Engineer


Allows the same functionality as Supervisor+ access level, with the additional ability to access t
he
Engineer screens, for setting up the EDT software.


PLEASE NOTE :
The Access Level can only be altered / read when in the Parameter Screen.








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Roll Limits


While in the Parameter Table Screen
-

by pressing the ‘Roll Limits’ Softkey, the Operator can
navigate to the Roll Limit Screen


the Operator can set the Roll
Limits, Headstock Direction and Start position.


The Roll limits
are used to define the working area of the roll


normally the length of the roll barrel. The Roll Limits
can be set
either
by typing in the valu
e or by jogging the EDT Texturing
Head to the desired position, then pressing the respective
softkey


‘Set Limit
-



or ‘Set Limit+’





Using the ‘Rotation CW’ or ‘Rotation CCW’ softkeys the
Headstock rotation can be specified by the

Operator. This
defines the rotation of the Headstock for all the EDT Cycles.




The Operator can specify the Start Position of the EDT Texturing
Head by either pressing ‘Start Headstock’ or ‘Start Tailstock’
softkeys.


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Diagnostic Screen


While in the Machi
ne Status Screen
-

by pressing the ‘Diagnostic’ Softkey, the Operator can navigate to the Diagnostic Screen


this screen would mainly be
used by the Maintenance staff. The screen will provide a graphical display of each of the Siemens IO racks within the
EDT system.



IO Rack


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Horizontal Softkeys


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Vertical

Softkeys


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Dielectric Tank Screen


While in the Diagnostic Screen
-

by pressing the ‘Dielectric Tank’ Softkey, the

Operator can navigate to the Dielectric Tank Screen


this screen would mainly
be used by the Maintenance staff. The screen will provide a graphical display of Dielectric Tank system within the EDT system
, as each Tank element turns on
the colour of the e
lement will change colour.





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Manual Control Screen


While in the Machine Status Screen
-

by pressing the ‘Manual’ Softkey, the Operator can navigate to the Manual Screen. The screen is used to view and edit
the current EDT parameters, and to Enable / Dis
able the EDT Servo Channels.




Horizontal Softkeys


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Servo Control


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EDT Parameters


Allows the Operator to
view and edit the current
EDT parameters.


Please Note

: The
parameters are not
update until you return
back to the Machine
Status Screen.



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Load and Save Screens


By pressing the ‘Load’ or ‘Save’ Softkey on the Parameter Table scr
een, the Operator can navigate to the Load or Save screen. The ‘Load’ screen allows the
Operator to load a EDT Data file and the ‘Save’ screen allows the Operator to save a EDT Data file.























The EDT data files are saved as
Comma
delimited file
s
(*.csv)
, and therefore can be opened and viewed / modified in Microsoft Excel (offline). The filename
can be a meaningful name .csv (complying to Microsoft Windows filename structure), allowing easier identification of the EDT
data file and

hence reducing
the risk of using the wrong program.


PLEASE NOTE

: The EDT Data file contains all the information required to Texture a roll.




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SECTION B

Commercial Issues







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B.1 Buyer’s responsibilities:


1)

Rolls drawings and
relevant information.

2)

Site information: location, available area to install the EDT machine and auxiliary equipment.

3)

Foundation work

4)

Custom clearance of equipment.

5)

Transportation to site

6)

Electrical and mechanical installation work including unloading the e
quipment and siting it

7)

Site work such as pit covers, hand rail, steps, safety fence,
work shop

lighting etc

8)

Duct for exhaust


9)

Primary electric source

10)

Other utilities required (air)

11)

Four (4
) CO2 cylinders for fire protection.

12)

Crane and Crane operation

13)

Rolls

for testing and commissioning on site.

14)

Grinding of rolls prior texturing trials on site

15)

Dielectric oil and lubrication oil for operation
.
Please note that Seller will not supply dielectric oil with the
machine and it is the
buyer’s

responsibility to provi
de the dielectric oil on site.






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B 2.0 Seller

s
Performance
Guarantee Figures and Test
/

Acceptance
Method


B2.1
Methodology


The following roll measurement procedure will be used for machine acceptance at Smart

Technology and after
installation
(Final
Acceptance
)

at the customer’s
site
:



a)

To determine the

surface roughness

Ra


and peak count

PC


of the textured

roll
,
a
n
umber of
measurements

shall be taken
.
Three locations along the roll axis will be chosen: one at 150 mm from
barrel end (head stock), the centre of barrel and 150 mm from barrel end (tail stock).
A
t
each location
(
4) readings in a distance of 1.5 to 3 mm apart paralle
l to the roll axis will be

taken.

The Ra and PC at
each location will be the average of the measured 4 readings.

The roll will be indexed to 90°, 180° and
2
70° and measurements will be taken again as described above.

Total number of measurements will be
12
.

b)

From each of the (12) me
asuring positions, the roll surface

Ra and PC
are

derived from the average of
the (12) location averages,

c)

Ra parameter is defined e.g. ISO 4287
-
1, DIN 4762 and DIN 4768. For the determination of roughness
parameters Ra < 2 or Ra = 2 with cut
-
off length λc

= 0.8 mm and Ra > 2 with cut
-
off length λc = 2.5
mm shall be performed.

d)

The peak count (Pc) is defined as the number of local peaks, which project through a selectable band,
centred on the mean line of roughness profile. For the determination of peak
count Pc slice levels at +
0.625 μm and


0.625 μm shall be used.

e)

For each roll surface texture uniformity is calculated as follows:


Ra uniformity =
Standard Deviation STDEV (Ra 12 readings)/ Ra average

PC uniformity = Standard Deviation STDEV (PC 12 read
ings)/ PC average


f)

For each set of rolls textured to the same target Ra /Pc value, repeatability will be measured as follows.


Ra repeatability= ((Ra average


Target Ra) / Target Ra

PC

repeatability= ((
PC

average


Target
PC
)

/ Target PC







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B2.2
Pre
-
Shipment (Shop)

Tests


Prior to shipment from Smart Technology’s works the following tests shall be completed.



1.

Prove all movements and functions of the machine



2.

Texture the following rolls:

Two ground rolls
will
be provided
for acceptance by

the seller
.

Each roll shall be textured within a specified time and shall be tested



The acceptance criteria being:




1.

Variation on each roll
(uniformity)
shall be no greater than
+

4% or
+
5%
(dependant on
Ra
) for

measurements of
Ra

and
PC
.


2.

Variation from roll to roll
(repeatability)
shall be no greater than
+

4% for
measurements of
Ra

and
PC
.


The customer or his appointed representative may witness trials if required.


On satisfactory completion of the tests Smart Technology shall issue a
pre
-
delivery acceptance certificate.



B2.3 Acceptance Tests at Customer’s Works

“Final Acceptance Tests”


On completion of installation and commissioning Smart Technology shall supervise texturing
a

number of

rolls
from the
ra
nge of rolls in use by the
customer.


Acceptance
Criteria



a)

System General Appearance / functions: Geometrical dimensions and
function of various component of the machine will be checked.

b)

System Interlocks

c)

Roll Loading and Unloading (all roll types)

d)

Automatic Operation Sequence

e)

Fire protection and CO2 release

f)

Texturing
test
s
: As described bellow.



Performance Gua
ra
ntees


Smart EDT system is gua
ra
nteed to produce the following performance.


Texturing Accu
ra
cy


Ra
nge of Roughness (
μm
)

Tole
ra
nce

(uniformity and repeatability) for Ra and PC
(+/
-
)
%

0.5 ~ 1.0

5

1.0~
3.5

4

3.5
~

6
.0

5


The requirement of the roll must be according to
the Roll Preparation Table bellow
.



Texturing times and PC are as shown in the following tables:



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Texturing
Acceptance Trials:


According to DIN and ISO standards 4287, 4288 and SEP 1940
.


This test is performed on
number of

test roll

(say 12 rolls as described here):



1.

The times required for texturing are as specified.


2.

The variation in surface texture
along each roll

(uniformity)

shall be no greater
than value stated in the following table,

to the ave
ra
ge reading
.


3.

The variation in surface texture within each roll
set

shall be no greater than
+

4%or 5% (dependant on
PC
)
to

the ave
ra
ge reading.




Machine Acceptance


Roll specification to be textured:


Diameter (mm)


Barrel Length (mm



Roll Prepa
ra
tion


Description

Quantity

Roll roughness prior to texturing

40% of Textured Roughness, ie,

Final roll textured surface = 1.5um
PC

Ground roll surface to be

0.6um
PC

Roll eccentricity

<0.015mm (and no high spots)

Grinding Marks and sc
ra
tches

None

Chatter

None

Feed Lines

None

Surface defects, C
ra
cks and Bruises

None



Acceptance Texturing Tests:


Number
of rolls

Roughness
Ra
(
μm
)

Standard Deviation
of
Ra and PC

Peak Count
(Peaks/cm)

Textur
ing Time

(mins)

4

2

+
4%



4

3

+
4%



4

4

+
5
%




Texturing Times for acceptance tests
+

10%




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Appendix
1

List of EDT Equipment Supplied by Smart


Please note that the following list shows EDT
equipment supplied by IMS / Smart (1996 to date), Spark Tec
(1987


1996) and T
ra
nsfer Technology Limited (1984


1989).


Smart Technology limited was established in 1994. Smart was originally called Intelligent Manufacturing
Systems limited. Smart acqui
red the IPR and business activities of T
ra
nsfer Technology Ltd (T
ra
nsTec) and
SparkTec. The Key personnel who were leading the EDT work in these organisation are now working for
Smart.


Spark Tec was acquired by Smart in 1996. Equipment supplied by T
ra
nsfer Technology Limited between 1984


1989, was based on Spark Tec patents currently owned by Smart. Also the equipment supplied by T
ra
nsfer
technology Limited was marketed, designed, manufactured, installed and commissioned while Dr M S Ahmed
was in ch
arge of T
ra
nsTec. Smart also acquired the business and Intellectual Property Rights assets from
T
ra
nsTec in 1995.


In 2008, Smart and Hengtong Machinery of Anshan, China established a joint Venture company to manufacture

and market the EDT equipment.
First machine was successfully completed in December 2008 and is currently

installed at PT Essar Indonesia , near to Jakarta.


Smart EDT machine installations

CUSTOMER

Year of Sale

APPLICATION

+British Steel, Port Talbot, UK

1985

Auto
-
body

*Krupp,
Germany

1987

Shadow Mask

+Modern Hard Chrome, East Chicago,
USA

1987

Auto
-
body and gene
ra
l

+Modern Hard Chrome, Warren, USA

1987

Auto
-
body and gene
ra
l

*Sundwig, Germany for export to
Russia

1988

Shadow Mask

+Modern Hard Chrome, Warren, USA

1988

Auto
-
body and gene
ra
l

+POSCO, Kwangyang, Korea

1988

Auto
-
body and gene
ra
l

*British Steel, Shotton, UK

1989

Auto
-
body and gene
ra
l

*Ohio Camshaft, USA

1989

Auto
-
body and gene
ra
l

+China Steel Corpo
ra
tion, Taiwan

1989

Auto
-
body and gene
ra
l

*Alusuisse
Swiss Aluminium,
Switzerland

1990

Auto
-
body

*Ohio Camshaft, USA

1991

Auto
-
body and gene
ra
l

*Ohio Camshaft, USA

1993

Auto
-
body and gene
ra
l






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CUSTOMER

Year of Sale

APPLICATION

*Dongbu Steel, Korea

1994

Auto
-
body

*Cold Metal Products, USA

1996

Special
application for
texturing small rolls

**Sumitomo Metal Industries Japan

1998

Auto
-
body

**Modern Hard Chrome, Warren, USA

(Not a complete system as the Customer
provided the roll rotation machine)

2001

Auto
-
body and gene
ra
l

**Modern Hard
Chrome, E Chicago, USA

(Not a complete system as the Customer
provided the roll rotation machine)

2
002

Auto
-
body and gene
ra
l

***PT Essar, Bekasi Fajar Industrial Estate

Bekasi, West Java, Indonesia

2008

Auto
-
body and gene
ra
l



In 2004 Smart won two
major cont
ra
cts for supplying EDT machines to two large Chinese Steel

companies. For unforeseen reasons, Smart declined to supply the equipment.



+ Supplied by T
ra
nsTec

* Supplied by SparkTec

** Supplied by Smart Technology

*** Supplied by Smart Hengt
ong