The basic design of tube and roll forming mills has changed little over the last 50 years. A series of gear-driven rolls form flat strip into the required profile. The dimension, shape and surface finish of the resulting product relies upon the accuracy of roll profiles and the expertise and experience of the operator. Despite the impact of computer technology in the design of rolls and roll drives, variations in material dimensions and properties, together with the difficulty of precise alignment and setting of the roll train, combine to make the manufacture of an acceptable product somewhat of a black art. Many of the problems associated with these variables, together with variations in roll dimension and setting, are exaggerated by the dynamic changes in drive point of the material on each driven roll. This article will describe the CyberDrive a patented system that reduces mill operating costs by automatically compensating for variations in drive point. Such a system overcomes many of the problems produced by these variations and provides a means of reducing drive power, roll and transmission wear and, at the same time, demonstrates a significant improvement in product quality.
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