Control and Automation systems for ferrous and non-ferrous rod, bar and sheet rolling mills including drive control, automatic gauge control, coolant control, tension control, shape control and mill setup modeling.
	Control and Automation systems for tube and forming mills.
	Control and Automation systems for press, stamping and bending machines.
	Control and Automation systems for melting furnaces.
	Control and Automation systems for billet, ingot and sheet casting.
	Control and Automation systems for finishing, leveling, slitting and cut-to-length lines.
	Control and Automation systems for annealing processes.
	Control and Automation systems for material handling and packaging.

Metals - Project Experience

The staff at Crosby Industrial Consulting, LLC has been involved in many control and automation projects in the metals industry. Our project involvements range from front-end feasibility and cost research to complete turnkey project management, design, installation, commissioning and follow-up system training and maintenance. The following is a summary of our staff's project experience in the metals industry:

ALCAN ALUMINUM, Oswego, NY - 88" single stand cold rolling mill - performed project engineering functions including the specification, design, programming, installation, commissioning and optimization of mill drive, sequencing and automation equipment. Served as Alcan's representative to the General Electric Drive Systems Department in Salem, VA during the mill design and programming phases.

ALCAN ALUMINUM, Oswego, NY - 100" multi stand hot rolling mill - designed, supplied, installed and commissioned a new DC drive system as part of a trimmer upgrade project.

ALCAN ALUMINUM, Oswego, NY - 100" multi stand hot rolling mill - designed, supplied, installed and commissioned a new trimmer width measurement and adjustment control system.

ALCAN ALUMINUM, Oswego, NY - 100" multi stand hot rolling mill - designed, supplied, installed and commissioned custom interface electronics to be used between new Farrand Industosyn units and an existing roll position control system.

ALCAN ALUMINUM, Oswego, NY - 100" multi stand hot rolling mill - designed, programmed and commissioned new "speed zoom" software to aid in achieving self-anneal rolling practices.

ALCAN ALUMINUM, Oswego, NY - 100" multi stand hot rolling mill - designed, programmed, installed and commissioned new master computer software and I/O hardware to achieve a mill parameter and control interface between an existing General Electric PMC system and a new Siemens MMC system.

ALCAN ALUMINUM, Oswego, NY - 100" multi stand hot rolling mill - designed, programmed, installed and commissioned I/O expansion hardware and programmable control software for coil stripping and delivery automation.

ALCAN ALUMINUM, Oswego, NY - 100" multi stand hot rolling mill - performed mill system evaluation and tune-up services for many years in support of an ongoing quality assurance program.

ALCAN ALUMINUM, Oswego, NY - ingot transfer system - designed, programmed, installed and commissioned new control systems for the transfer of ingots from a new preheat furnace via a transfer car as well as from existing soaking pits via a transfer crane.

ALCAN ALUMINUM, Oswego, NY - melting furnace - designed, programmed, installed and commissioned a new melting furnace control and parameter trending system utilizing touch screen MMI and programmable control equipment.

ALUMAX MILL PRODUCTS, Lancaster, PA - multi stand aluminum hot rolling mill - provided a mill performance appraisal, data acquisition, Functional Requirements Document and bid package for a major upgrade project.

ALUMAX MILL PRODUCTS, Texarkana, TX - single stand aluminum cold rolling mill - provided drive, control and AGC system appraisals and implemented remedial actions to resolve tension and gauge control problems.

CHINA STEEL, Kao Hsiung, Taiwan - multi stand hot rolling mill - retained by Siemens Energy & Automation as a control and automation interface consultant during the sales phase of a major mill upgrade proposal.

COMMONWEALTH ALUMINUM, Lewisport, KY - single stand cold rolling mill - designed, installed and commissioned drive system modifications to accommodate laser speed measurement and tension control in conjunction with a mass flow gauge control system.

CRUCIBLE SPECIALTY METALS, Syracuse, NY - single stand steel bar mill - commissioned and optimized new drive and control systems as part of a major mill upgrade.

DELPHI HARRISON THERMAL SYSTEMS, Lockport, NY - five stand aluminum cold rolling mill - specified, designed, programmed, installed and commissioned new control and automation systems including AGC, HMI, SCADA, PLC, process computers, coolant sprays, inter-stand tensiometers, roll position measurement, automatic mill setup and system networking for a project to modify the original copper/brass mill to roll aluminum fin and tube stock.

NUCOR STEEL, Auburn, NY - three strand billet caster - performed billet cutting and handling analysis including time studies, design of sequencing automation upgrade architecture and project cost report in preparation for a control and automation upgrade.

REVERE COPPER PRODUCTS, Rome, NY - single stand copper/brass rolling mill - assisted Siemens Energy & Automation with commissioning new drive control and automation systems as part of a major mill upgrade.



Back to Industries