1. COLD MILL FEED DEVICE:
DRIVEN PIVOTING
PINCH ROLL
Ted Tracewicz
Project Engineer

2. EXECUTIVE THEOREM ON SALARY
 This theorem on salary states that
engineers and scientists can never earn as
much salary as business executives and
sales people.
 Postulate 1: Knowledge is…...
 Postulate 2: Time is……

3. POSTULATES
 Postulate 1: Knowledge is power
 Postulate 2: Time is money

4. EVERY ENGINEER KNOWS:
 WORK/TIME = POWER
 but, KNOWLEDGE = POWER
 and TIME = MONEY, therefore,
 WORK/MONEY = KNOWLEDGE

5. SOLVING FOR MONEY
 WORK / KNOWLEDGE = MONEY
 THUS, AS KNOWLEDGE APPROACHES
ZERO, MONEY APPROACHES INFINITY
REGARDLESS OF THE WORK DONE

6. CONCLUSION
 THE LESS YOU KNOW, THE MORE YOU
MAKE.
 BUT…..
Unigraphics
Solutions
….THE MORE YOU KNOW THE LESS TIME IT
TAKES TO GET THE SAME WORK DONE!

7. ATS SPARTEC INC.
 Metal Strip Process Original Equipment Manufacturer
 ATS Spartec designs and builds a full range of high
quality robust metal strip processing machinery and
integrated lines for the ferrous and non-ferrous
industries, which include:
 Coil Handling Equipment: -Strip Feeders, Mandrels
 Coil Processing Equipment: -Strip Cleaning Lines, Dryers
Coil Coating Lines, Hi-Cure Infra Red Gas Fired Ovens
 Coil Packaging Systems
 Slitting Line Retrofits
 Wire Spooling Systems

8.  Mechanical Engineering:
 CAD Design Services- Solid Edge, AutoCAD
 Hydraulic, Pneumatic Systems, Design
 “Special Component” Design/Build
 Special Purpose Machinery Design
 Stress Analysis
 Electrical Engineering
 Control Systems: PLC Programming (new & existing)
 Modicom - Siemens - Allen Bradley - Omron -GE - Cegelec
 Operator interface design & programming
 Control Panel Design/Build
 DC Drive Applications Modernization
 Project Management

9. INTENT FOR THIS PRESENTATION
 Document the evolution of a NON-STANDARD
product from:
 Customer’s problem
 Proposal -Order
 Design to drawings issued for construction
 Manufacture/Assemble/Test
 Installation/Operation
 All of the above from the perspective of the
benefits of 3D modeling.

10. CUSTOMER PROBLEM
Feeding strip metal into mill is labor-intensive
and poses a safety issue.

11. ATS SPARTEC PROPOSAL:
 01. ATS Spartec Inc. Neoprene Covered Steel Pinch Roll, with
Hydraulic Orbit Motor Drive and control valves.
 Roll lift is by two mill style Hydraulic Cylinders. Roll housing allows
for 25 degree pivot via links connected to existing deflector roll
neck. Actuation is from a single mill cylinder tied into the new pinch
roll housing and mill frame.
 Modification of the existing deflector roll and chocks are by
Customer according to drawings supplied by ATS Spartec.
 Customer is to supply as-built drawings of existing Equipment.
 02. ATS Spartec Inc. Hydraulic Control Valves for pinch roll and
actuator including solenoid operated directional valves and flow
controls.

12. COLD MILL FEED DEVICE:
DRIVEN PIVOTING PINCH ROLL

13. RECEIVED PURCHASE ORDER
DELIVER AS SOON AS POSSIBLE

14. DESIGN
 DEFINE EXISTING GEOMETRY
 EXISTING PART/ASSEMBLY
MODIFICATIONS
 ROLL
 DRIVE
 FRAME
 PIVOT & HYDRAULICS

15. “EXISTING ASSEMBLY”

16. EXISTING PART/ASSEMBLY
MODIFICATIONS
 DEFLECTOR ROLL CHOCKS
 CHOCK SUPPORTS

17. DEFLECTOR ROLL ASSEMBLY

18. ROLL GEOMETRY -SOLID EDGE
 Part/Assembly: -PrtSc in Word document

19. SPLINE-CONNECTED DRIVE?

20. INTERFERENCE -Try Offset Drive & Cplg.

21. SOLID SQUEEZE ROLL
 PROPOSED GEOMETRY

22. SQUEEZE ROLL -DRIVE END

23. ROLL ANALYSIS
 CLASSICAL MECHANICS -BENCHMARK
 FINITE ELEMENT ANALYSIS -ANSYS
 DID NOT HAVE TO DRAW IN ANSYS
 DIRECT IMPORT -did not have to build
geometry in FEA program which would not
be as productive as in Solid Edge.
 EASY DEFEATURING
 DEFINE MATERIALS

24. GENERATE MESH
 130,000 ELEMENTS

25. REFINE MESH
 ONLY SEVERAL THOUSAND ELEMENTS!

26. ROTATING BRICK MESH
CONVERTED TO PARASOLID
FILE, -IMPORTED INTO ANSYS

27. APPLY LOADS
 REACTIONS UNDER LOAD
 NOTE 1/2 SYMMETRIC MODEL

28. OBTAIN SOLUTION
 STRESS PROFILE

29. LOCAL STRESS CONCENTRATION

30. LOOKING FOR HIGH STRESSES

31. DEFLECTION PROFILE

32. DRIVE DESIGN
 HYDRAULIC ORBIT MOTOR
 COMPACT
 TIGHT SPACE CONSTRAINT
 HIGH TORQUE

33. FINAL ROLL-DRIVE ASSEMBLY

34. EXPLODED Dft USEFUL FOR
ASSEMBLY & MAINTENANCE!

35. FRAME DESIGN
 MILL DUTY -ROBUST
 SPACE CONSTRAINTS -FIT TO EXISTING
ASSEMBLIES
 FEA?
 EASY TO MODIFY

36. FRAME ASSEMBLY DRAWING

37. PLATE SUB-ASSEMBLY -A

38. QUICK FEA
 COSMOS/EDGE

39. PLATE SUB-ASSEMBLY -A

40. PIVOT DESIGN
 LOCATION OF HYDRAULIC PIVOT
CYLINDER
 HYDRAULIC SCHEMATIC

41. USING SKETCH TO OPTIMIZE PIVOT

42. HYDRAULIC SCHEMATIC

43. KEEPING TRACK OF DESIGN
 DRAWING PRODUCTION
 DRAWING FILES
 CUSTOMER FEEDBACK

44. BROUGHT IN TITLE BLOCK FROM
ACAD -SIMPLE

45. EXCEL FILE DRAWING LIST
 NOTE DWG FILE VS CAD FILE
JOB 4027 DOFASCO PIVOTING PINCH ROLL -DRAWING LIST
NO. DATE TITLE DWG. NO. CAD FILE REVISION COMMENT
1 10/21/98 Pivoting Pinch Roll G.A. G40270100 -Sht 1 of 4 G40270100PivotPRRev30.dft 1 Submitted to Dofasco 7/30/99
2 11/9/98 Pivoting Pinch Roll G.A. G40270100 -Sht 2 of 4 G40270100PivotPRRev30.dft 0 Submitted to Dofasco 7/30/99
3 10/21/98 Pivoting Pinch Roll G.A. G40270100 -Sht 3 of 4 G40270100PivotPRRev30.dft 0 Submitted to Dofasco 7/30/99
4 10/21/98 Pivoting Pinch Roll G.A. G40270100 -Sht 4 of 4 G40270100PivotPRRev30.dft 0 Submitted to Dofasco 7/30/99
5 2/1/99 HYDRAULIC SCHEMATIC S40270201 4027Hyd4.dft 4 Submitted to Dofasco 6/21/99
10/27/98 Hydraulic Cyl -4x20 H40270202/0104.031.0304 HydCylLincAH4x20Extend.par 0 Submitted to Dofasco 7/30/99
10/27/98 Hydraulic Cyl -4x8 H402702030104.062.0121 PivHydCylAH4x8retr1.asm 0 Submitted to Dofasco 7/30/99
10/27/98 Electrical E40270301 N/A
6 10/21/98 Frame General Ass'y M40270400 G40270100PivotPRRev9.dft 2 Submitted to Dofasco 7/30/99
7 10/21/98 Top Plate Detail M40270401 TopPlPR1.dft 3 Submitted to Dofasco 6/21/99
8 10/21/98 Side Plat -Op.S., Out Assy M40270402 SidePlAssOpOut2.dft 2 Submitted to Dofasco 7/27/99
9 10/21/98 Side Plat -Op.S., In Assy M40270403 SidePlAssInOp3.dft 1 Submitted to Dofasco 7/27/99
10 10/21/98 Side Pl -Dr. Side In Assy M40270404 SidePlAssInDr2.dft 1 Submitted to Dofasco 7/27/99
11 10/21/98 Side Pl -Dr. Side Out Assy M40270405 SidePlAssInOpDr2.dft 1 Submitted to Dofasco 6/21/99
12 10/21/98 Vert.Side Pl. Op SideT Det M40270406 VertSupPlOpOutTop1.dft 2 Submitted to Dofasco 6/21/99
13 10/21/98 Vert.Side Pl. Op Si.Bot Det M40270407 VertSupPlOutOpNotch2.dft 2 Submitted to Dofasco 6/21/99
14 10/21/98 Squeez.Roll Chock Gib Det M40270408 ChockGuide1.dft 1 Submitted to Dofasco 6/21/99
15 10/21/98 Vert.Side Pl Op In Top Det M40270409 VertSupPlOpInTop1.dft 1 Submitted to Dofasco 6/21/99

46. MANUFACTURING
 PRE-MACHINE PLATES
 ROLL
 WELDMENTS
 SUB-ASSEMBLY
 ASSEMBLE
 QUICK MODIFICATIONS
 FINAL ASSEMBLY

47. FITTING & ASSEMBLY

48. ASSEMBLY & PIVOT TEST

49. HYDRAULIC TESTING
 SQUEEZE CYLINDER STROKE
 PIVOT CYLINDER STROKE
 TURN HYDRAULIC MOTOR

50. CHECK CHOCK STRESS AREA

51. LAST MINUTE INTERFERENCE

52. CLOSER LOOK

53. DRAWING TO ASSIST CUSTOMER

54. CHECKING SIDE GUIDE
INTERFERENCE

55. NOTCH-OUT EXISTING HOUSING

56. TRIED TO SELL LIFT-BAR

57. FINAL ASSEMBLY

58. TOTAL ASSEMBLY WEIGHT
 Physical Properties Report
 Volume= 29896.061 in^3
 Mass= 8879.765 lbm
 With respect to the Global Coordinate System
 Center Of Mass:
 X= -2.816 in
 Y= -0.362 in
 Z= 14.900 in
 Center Of Volume:
 X= -1.738 in
 Y= -0.380 in
 Z= 14.686 in
 Mass Moments Of Inertia:
 Ixx= 4987845.896527 lbm.in^2 Iyy= 14972262.703515
lbm.in^2 Izz= 10458228.446378 lbm.in^2
 Ixy= -159161.559421 lbm.in^2 Ixz= -1051724.967042

59. ASSEMBLY IN PIVOT POSITION

60. ASS’Y. FRONT & HYDRAULIC DRIVE

61. SQUEEZE ROLL IN CHOCK &
COUPLING GUARD

62. DEFLECTOR ROLL & JOURNALS
TOP HYDRAULICS

63. PLUMBED, PAINTED -SHIP IT!

64. DELIVERY
 SHIP UNIT
 PROVIDE CUSTOMER MANUAL
 PROVIDE CAD FILES

65. According to the Customer….,
 “Hi Ted:
 I have an update on the status of the
drawing conversion. Our guy in EMT is
having very little difficulty in converting the
files to our standard.
 The only minor difficulty … is that the
symbol for degrees ….and … diameter are
not translating correctly. …. That seems to
be the only stumbling block”

66. INSTALLATION
 SMOOTH - “FITS LIKE A GLOVE”
 OPERATOR HAPPY WITH UNIT -FLEXIBLE
SAFE, SAVES TIME!

67. CONCLUSION
 DESIGNING IN SOLID EDGE HELPED IN THE
FOLLOWING WAYS:
 AVOIDED INTERFERENCES BETWEEN NEW
AND EXISTING PARTS CONSEQUENTLY
ALLOWED A SMOOTH INSTALLATION
 3D ALLOWED EASY FEA
 DRAWINGS EASILY AND SUCCESSFULLY
CONVERT TO dxf, dgn, dwg WHICH
HELPED MANUFACTURING AND
CUSTOMER WHO USED ANOTHER CAD
SYSTEM

68. INSTALLATION IN MILL
 MANDREL READY TO ACCEPT COIL

69. PINCH ROLL WINDOW OPEN
 HAPPY OPERATOR

70. Pivot, Pinch, Retract, Feed, Open

72. THANK-YOU FOR YOUR TIME!