Copper Rolling Mill

In the early 90s, as one of the world's leading producers of copper-based alloys, Olin Brass Corporation, selected a Wheelift® technology mobile roll changer for use within their 1,700 acre complex producing copper and brass sheet & strip products for U.S. and world markets.

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In 1992, Olin Brass Corporation built a new brass rolling mill on the outskirts of St. Louis. One of the innovative new systems installed at that time was a totally unique, heavy capacity Mobile Quick-Change Roll Changer consisting of a custom designed multi-axle transporter. It was designed to carry matched mill rolls to the operations area, position and dock at any one of fourteen mill roll positions, then automatically remove worn rolls from the rolling mill and install the new or reconditioned ones. The system revolutionized Olin Brass's operations and has operated reliably since the early 1990's, with no indication that it will be replaced in the foreseeable future — a solid testimonial to robust reliability the Wheelift® technology provides.

In 1992, a "Mobile Roll Changer" was a totally new unproven concept that used fluid equalizing suspension and computerized steering control to manage six heavy capacity, on-center rotation urethane wheeled axle assemblies. Each axle assembly was rated at 40,000 pounds, for a total gross load capacity of 120 US tons.

The fluid suspension system for the six on-center rotation axle assemblies has the axles divided into three groups. The two axles in each group have interconnecting fluid lines for load sharing to ensure every wheel carries only its specific portion of the load, regardless of variations, slopes, and irregularities in the floor surfaces. Floor loading is dispersed with ground pressure loads spread over a wide footprint.

Process-driven features include a system monitor, on onboard driver station, 3% slope capability, five inches of vertical travel for docking and undulating travel surface compliance, along with the side-by-side extractor assemblies that shuttle the rolls in and out to the mill's roll stands. The transporter's hydraulic system is powered by a small GM engine converted to LP gas.

CHALLENGE: Instead of the traditional methods of having fixed roll changers at every mill roll position, Olin Brass desired a highly dependable mobile quick-change roll changer, capable of performing 5-minute swap-outs of matched roll sets in a high production brass rolling mill environment that was challenged with severely uneven and oily floors, along with major space limitations and severe aisle congestion.

SOLUTION:A man-aboard 120-ton gross load wheeled transporter with dual roll extractors, where the transporter aligns and locks in position to extract the worn roll, then releases and drives laterally to reposition and insert the replacement roll. Such a system for that type of capability did not exist at the time. The mill machinery manufacturer became aware there was an active design for an equalizing axle concept that would make such a mobile roll changer possible. They acquired the plans and built the first-ever mobile roll changer which proved to be an instant success.

BENEFIT:

• 5-minute roller set swap-out
• Increased mill line efficiency
• Controlled work process
• Single mobile roll changer Vs fourteen fixed location roll changers.
• High reliability
• Expanded utilization

The self-loading Wheelift technology transporter provides Olin Brass with congested area plant utilization that is totally independent of overhead cranes. The transporter provides the needed heavy capacity with a degree of flexibility not attainable through other technologies to this day. Worldwide niche markets drive manufacturing flexibility for product customization and configurable work processes. Wheelift Transporters and AGVs facilitate this requirement in a way that so far has not been duplicated.

Wheelift Transporters and AGVs are manufactured in Iowa and are custom engineered to application specific requirements. Chassis and fixtures are available with load capacities to 500+ tons and deck heights as low as 18.5". Power options include diesel, LP gas, battery, or umbilical cord. Computerized all electric omni-directional drives are standard with individual axle ratings of 15, 20, or 25-ton.

Wheelift® is now a Doerfer Companies technology. Doerfer engineers and builds application specific manufacturing machinery and systems. Operating from four North American locations with over 700,000 sq. ft. and 500+ employees, Doerfer offers expanded technical and manufacturing resources, is NQA-1 certified, and closely follows ISO 9001 standards.

SUMMATION: For Olin Brass Corporation, their twenty years of trouble free operation of their Wheelift technology mobile quick change roll changer has made a major contribution to their profitable operations in producing brass and copper from their mill operations, where they operate 24 hours.

TRADEMARKS

The following terms that are used through this website: Wheelift^®, Uniload^®, SynchroSteer^®, StackAxle^®, TrackAxle™ and OmniAxle^™ are all trademarks that are exclusively licensed to Doerfer Companies.