Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Brush Rolls
Non-woven Rolls
Mission statement
With the ability to connect global competence Reliability and sustainability in terms of our
in the best possible way for our customers customers, employees and company deter-
alongside the provision of local, extensive mine our actions. At the same time, the prin-
service, we develop and manufacture innova- ciple of responsible and careful management
tive, quality products and solutions targeted of our environment and its natural resources
for machine system engineering and opera- applies to us at all times.
tors of rolling mills and strip processing line
technology.
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Content
1 Introduction Page 3
3.2 Factory Assembly (FA) brush roll systems, Integrated Maintenance Service Page 21
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OSBORN International
1 Your competend partner in surface finishing solutions - worldwide
Companies all over the world rely on the quality and effi- close complex service network of the other OSBORN busi-
ciency of OSBORN. With a total of twelve sites, high quality nesses and branch offices or local service partners provide a
tools are developed and manufactured for processing sur- comprehensive service for our customers’ rollers anywhere
faces for use in a variety of branches in industry. in the world.
Brazil • China • Denmark • France • Germany • Great Britain • India • Mexico • Portugal • Romania • Spain • Sweden • USA
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High-quality raw materials, years of experience, modern but we are not satisfied with that. Constant innovation and
manufacturing techniques and careful workmanship. These product development are of central importance to us, both in-
are important criteria which provide the consistently high house and in close cooperation with technology partners in
quality of OSBORN products. Quality assurance accompanies Europe, Asia and North America. We seize the incentive of
all stages of production. It is fully integrated into the process- making our range of services, and with it the products and
es and certified in accordance with DIN EN ISO 9001-2000. processes of our customers, better, faster, more reliable, safer
This has made us the world’s Number 1 in brush technology, and more environmentally friendly.
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The demands relating to the quality and the technical prod- in comparison to conventional brush rollers sets new stan-
uct characteristics of flat rolled steel in the form of cold dards in the degreasing and cleaning of strip surfaces.
rolled steel, tin plated steel, electrical steel, galvanized strips Through the consistent further development of the most
or other refined surface materials are steadily rising. Along important quality criteria (fill material, brush construction
with increasing processing speeds, the logical requirement and fill density) and at the same time by optimising the
for optimising the tempering, refinement or coating process using parameters, significant improvements can be
of the upstream strip cleaning section arises. achieved in terms of the brush lifetime / cleaning perform-
ance and with it, apart from the technically qualitative
With the development and introduction of the HDL® brush aspect, a reduction in operating and maintenance costs can
roller, OSBORN has found an answer to this problem, which also be realised.
Application category Metallurgic field Process line Description of application OSBORN product range
Different demands are made on the brush depending on the OSBORN HDL® brush rollers are therefore individually tai-
type and degree of soiling of the primary material as well as lored to the relevant case in hand. At the same time, multi-fil-
the strip cleanliness required for the subsequent process aments and special mono-filaments can be used with or with-
step. While optimum degreasing and micro-cleaning can be out an abrasive portion as single bristle or mixture filaments.
achieved with non-abrasive multi-filaments, abrasive fila-
ments are ideally suited for the removal of strongly adhesive
rolling retentions from the previous rolling process.
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The activation of the strip surface is an important task both in In the next process step, an activation of surfaces then takes
the production of rolled claddings as well as in the coating place by generating a defined roughness using abrasive or
and/or finishing of strip steel, tinplate, electrical steel strip wire brushes. A similar process also happens in continuous
and other materials. In rolled cladding, the core and, if neces- strip coating. In both cases, an optimal adhesion is guaran-
sary, the overlay strips or plates have to be freed initially from teed for the subsequent rolled cladding and/or organic or
oil, grease, dirt, carbon particles and oxides with the help of metallic coating through surface activation.
brush rollers in alkaline cleaning or acidic pickling processes.
Application category Metallurgic field Process line Description of application OSBORN product range
Here too, HDL® rollers from OSBORN create an ideal combi- This is a challenge that OSBORN has set itself for years and
nation of the different brush functions which are required. The through which we have worked out a technological advan-
non-abrasive multi-filaments ensure optimum micro-cleaning tage for ourselves in the production of brush rollers with the
as the abrasive filament mechanically intensifies this through development of innovative microfilaments and brush con-
its abrasive effect and at the same time, generates the surface structions as well as even higher quality standards.
activation which is required. The grinding agent, grain size,
facing density and abrasive portion are also individually
adjusted to the respective individual application.
In steel sheet coating, the brush roller has long been promot-
ed as an absolute high-performance and precision tool in the
case of thicknesses of <0.15mm, coating thicknesses of 0.05g
/ m² and ever higher line speeds. At the same time, the indi-
vidual demands made on the brush can be quite different
depending on the flatness, surface hardness of the starting
material and the nature of the subsequent coating or plating.
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For cleaning work and back-up rolls in wet or dry operated neutrally ground at the radius and axially and either gains a
rolling and skin-pass mills, OSBORN’s Helimaster brush cylindrical camber ground, or for offsetting the computed roll
rollers have characterised worldwide technological develop- deflection, a positive and/or negative camber ground.
ment for decades, both in online lines integrated in strip lines
as well as stand-alone off-line rolling stands. In the meantime, with Lipprite® abrasive rollers, an alternative
technology has also been developed and manufactured in-
In doing so, the rollers can work sporadically or continuous- house for skin-pass roller cleaning.
ly, designed as a wire or an abrasive brush. Each brush is
Application category Metallurgic field Process line Description of application OSBORN product range
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When it comes to the optical finishing of strip surfaces in Apart from high-quality wire and abrasive brushes, we can
the form of polishing, sanitising, finishing or decorative at the same time rely on the merger with the Lippert-Unipol
grinding and brushing, you’re in good hands with OSBORN. Group, one of the global leaders in abrasive and polishing
Decades of experience in the machining of steel, stainless tools, using polishing and abrasive rollers and polishing
steel, aluminium or other non-ferrous surfaces have given pastes on a selection and combination of tools and pro-
us a technological advantage, from which today our cus- cessing alternatives, which is unique in the market. Use this
tomers benfit worldwide. advantage to optimise your process - for perfect surface fin-
ishing.
Application category Metallurgic field Process line Description of application OSBORN product range
Oxide removal, polishing Brush rolls abrasive or wire-
Carbon steel
and finishing of hardened filled; Bessemer-wire brush
Strip polishing and finishing Stainless steel and tempered strips rolls; OSBORN HDL®
PL, APL , FL
Aluminium Oxide removal, polishing, Technology; Lipprite® abrasi-
finishing and generating ve non-woven rolls; UNIPOL®
Non ferrous
decorative surfaces polishing emulsion
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UNIPOL® polishing emulsions are initially directly applied to Our Lipprite® product series represents an alternative to
the strip surface to be processed as a liquid paste in immer- brush rollers with a wire or abrasive bristle coating, as with
sion baths or by means of a low-pressure, medium-pressure, grinding non-woven rollers, an absolutely uniformed fine
high-pressure or airless spraying system. final grind and a corresponding homogeneous surface finish
With Bessemer wire measuring diameters of 0.06 or 0.08 can be achieved. With the correct contact pressure, the flexi-
mm, filled rollers serve as carriers of this paste in the subse- ble roller surface is in a position similar to a brush, to offset
quent polishing process. any slight unevenness of the strip.
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In de-scaling strip surfaces after the hot and cold mill process, been possible to achieve tremendous quality and improve-
our brush rollers have been setting standards in strip lines for ments relating to service life on numerous strip lines and with
years. OSBORN’s developments and innovations both on the it, a substantial reduction in the total cost. The parallel opti-
part of brush construction as well as filaments have in the misation of the brush / shaft design and operational parame-
meantime set the international standards in annealing and ters through targeted assistance on site with the customer is
pickling lines or bright annealing lines for stainless steel strip. another important OSBORN competence based on our long-
standing worldwide experience. Set us a challenge!
With the development of acid resistant fill materials it has
Application category Metallurgic field Process line Description of application OSBORN product range
Carbon steel CPL Heavy duty descaling prior Brush rolls abrasive or wire-
HAPL to acid pickling filled; Heavy abrasive brush
Scale removal Stainless steel rolls; OSBORN HDL®
HAPL Heavy duty descaling between acid tanks Technology; Lipprite® abrasi-
Non ferrous HRM Scale and dirt removal prior to rolling ve non-woven rolls
Through the development of special abrasive and non-abra- out of acid or other corrosive media from the brush lining. On
sive facing materials combined with a much improved level the one hand, an optimum rinse function is ensured by the
of acid resistance and with that good wearing properties, the correct number and size of the cooling holes and the other by
lifetime of brush rollers in stainless steel strip lines has now the correct choice concerning the quantity of liquid.
been significantly increased. This allows tremendous cost
savings in the form of longer lifetimes and lower mainte- At the downstream strip drying operation, similarly signifi-
nance costs. cant process improvements and substantial cost savings can
be achieved through squeezing rollers using newly devel-
Ideally, the abrasive rollers are inserted on roller systems oped acid-resistant non-woven materials as well as vacuum
made from hollow shafts with bore holes. Apart from systems.
improved cooling of the filaments in the continuous opera-
tion of the roller, these also provide the continuous rinsing
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In manufacturing stainless steel flat products, OSBORN • NOVOTEX® squeezing rollers with an acid resistant non-
International’s intelligent solutions and innovations play a woven covering
part in process optimisation and quality improvement as well
as being deployed for de-scaling hot and cold mill strip sur- • Helimaster brush rollers for cleaning rolls in skin pass mills
faces at many other levels of the value chain:
• Vacuum squeezing roll systems as an energy saving replace-
• HDL® brush rollers with a micro-fibre brush for careful and ment strip dryer
thorough cleaning of sensitive strip surfaces
• High temperature brush transport rolls for hot and cold strip
• Acid and temperature resistant brush sealings on continuous furnace lines
• Lipprite® abrasive rollers for surface finishing and follow-up • Brush transportation rolls for reducing noise on slitting and
processing plates and strips cross-cutting lines for heavy plates
• Braking, tension, deflection or pressure rollers made from a • LOAD RUNNERS® heavy load rolls in coil transportation
non-woven covering for replacing rubber or polyure- devices or roll exchange vehicles.
thane rollers
Steel mill Hot rolling mill Pickling line Cold rolling mill Anealing and pickling line
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Almost 50 years ago, OSBORN developed a revolutionary ities, abrasive multi-filaments, individually camber ground
technology using brushes in the continuous rolling process surfaces and extensive experience in optimising the use of
in order to optimally regulate the oxide film on working and brushes in numerous individual applications have secured
back-up rollers in hot rolling mills. Meanwhile, hundreds of a big technological advantage for us in this field, from
rolling hot mills worldwide have been equipped with which our customers benefit worldwide.
OSBORN technology. To date, specially designed wire qual-
Application category Metallurgic field Process line Description of application OSBORN product range
Aluminium HRM, HRFM, HFM Control of the oxide layer Helimaster® Brush rolls
Roll coating control
Non ferrous HCM and removal of oxides abrasive or wire-filled
Lateral rings made of composite fibre materials for limiting On hard chrome working rollers, abrasive multi-filaments
immersion depth and sleeves for splash guarding journals with a high density achieve a particularly uniform brushing
and bearings - developments created by OSBORN. and cleaning of the roll surfaces.
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The individually adapted camber ground of the brush roller brushed, and the calculation of the optimum crown is car-
body is one of the most important prerequisites for ensur- ried out. OSBORN of course also grinds brush rollers with
ing uniform brushing across the entire width of the roll. a CVC contour on CVC technology mills for roller gap
Convex or concave contours are ground, depending on the adjustment.
construction of the working or back-up rollers to be
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The tempering of hot mill plates made of precipitation hard- of up to 600°C on brushed transportation rolls. In close coop-
ening aluminium alloys through the process of solution eration with leading equipment manufacturers, numerous
annealing serves the purpose of attaining higher strength and furnaces around the world have been equipped in recent
strain values along with a good level of corrosion resistance years with OSBORN’s sophisticated technology. In the
for the material. Today, this is required for structural parts in process, plates with thicknesses of up to 400mm, lengths of
aircraft in accordance with the high requirements of stan- 20 metres and weights of over 10 tonnes do not represent a
dards AMS 2750D, AMS 2750C and AMS-H-6088. problem for us. Tolerances have been continually reduced
The careful transportation of these aluminium plates in ‘hard and product features optimised, so that now more than ever,
metal and hard material technology’ roll hearth furnaces the brush roller is an important and technically superior com-
takes place as a batch or reversing process at temperatures ponent in the overall design of the line.
Application category Metallurgic field Process line Description of application OSBORN product range
With brushed furnace transportation rolls, OSBORN cus- For roll assemblies in new furnace lines, this allows OSBORN
tomers can today place their trust in several decades of expe- to guarantee an optimum course of the sheet within tight tol-
rience and well known global references. In the complex pro- erances even when starting up the run.
duction of the rolls, some with a total length of over 6000mm
and 4000mm of brushed length, the highest levels of preci- In order to guarantee the lowest possible of amount of sheet
sion and reliability are required in all manufacturing process- tracking, with the ‘re-brushing’ of entire furnace zones, the
es. transportation of the sheets is simulated on an in-house test
After the rolls have been manufactured, the later course of rig just like new lines.
the sheet is accurately simulated in advance in our factory.
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Roll coverings made from extremely dense stainless steel rollers with ceramic coatings. These can be used in different
wires in special alloys which are resistant to high tempera- horizontal heat treatment lines for strips of steel, stainless
tures provide specific product features and strong advan- steel or nonferrous metals.
tages compared to uncoated transportation shafts or furnace
Application category Metallurgic field Process line Description of application OSBORN product range
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When transporting the sheets onto rolling tables, extreme By coating the bright transport rollers with brush sections,
noise levels may occur in slitting/cross cutting lines for heavy the noise level can be reduced to around 70 dB so that a risk
plates after the shearing process. At over 110 dB, this may to health in terms of occupational health and safety is signif-
possibly exceed the threshold of noise pain for the human icantly reduced.
ear.
Application category Metallurgic field Process line Description of application OSBORN product range
Carbon steel
Transport roll systems Stainless steel Low noise surface friendly Noise-reduction transport
SL, CCL transport
for noise reduction transportation of plates or rolls; Noise-reduction
Aluminium roll tables
sheets transport roll systems
Non ferrous
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Through many years of cooperative development work with around the globe in all stages of project development, from
machinery manufacturers in the design of rolls and brushing the initial design to commissioning. A whole host of well-
machines as well as with the operators concerning produc- known manufacturers in the business of strip and heat treat-
tion line and process optimization, OSBORN has an estab- ment plants and rolling mill technology benefit from this
lished wealth of experience in this field. Through our world- expertise which ultimately rewards the plant operator in the
wide sales and service network we are able to guarantee form of well-engineered products and innovative technolo-
comprehensive technical support for new production lines gies.
Splash rings
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At OSBORN, decades of global expertise is consistently com- OSBORN factories or local partners spread over many coun-
bined with a local, comprehensive all-round service package tries offer a comprehensive service for your rollers. This
on the customer’s premises. In addition to six centralised allows customers around the globe to directly benefit from
technology centres in Asia, Europe and North and South our technology and the comprehensive range of services on-
America, the other service centres belonging to the various site.
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Conditioning
Reworking
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OSBORN has the right solution for customers who want to different shaft that a customer has, like no other manufactur-
recover and maintain their brushes in-house – roller systems er in the world.
for self-assembly. Our range of products and services
includes cassettes in fully-automatic internally-welded spiral At the same time all of the usual filaments, wires or natural
constructions, disk constructions as well as constructions bristles can be processed and realised according to individual
assembled on one-way tube bodies and older structures with requirements at different trim lengths and densities - from
single discs or loose spirals. In order to individually adapt light to standard, to extremely dense.
these to existing shaft constructions, they are additionally
provided with one-way adapters, if required. We also provide the right equipment for simple follow-up
As such, we can supply the right cartridge for almost every shearing of the roller on a lathe.
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OSBORN International once again sets a new benchmark in properties. In addition, the expertise from years of close
brush technology with HDL® brush rollers - the latest devel- cooperation with technology partners and line manufacturers
opment from us. By combining streamlined brush construc- in Japan, Europe and the United States as well as from the
tion with specially developed micro fibre fill materials, it has ever increasing demands on line operators has been brought
been possible to realise and successfully introduce a product together.
with significantly improved performance levels and wear
Individual concepts improved brushing application in process lines (lifetime and brush performance)
OSBORN HDL® conceals even more than this. What we mean individual covering is defined for the roller which is made
by this is an optimisation approach to strip lines with regard from non-abrasive and/or abrasive micro fibres and monofil-
to the various brush applications as well as the usage param- aments. In parallel, the shaft construction is optimised and
eters of these rollers. adjusted. In general, the customers’ existing shafts can be
used. In addition, the usage parameters of the respective
Initially, the current weaknesses will be analysed. Depending brush rollers are evaluated with regard to cooling, in-feed and
on the type of line and degree to which the brushes are revolution speed and an individual optimisation recommen-
required for cleaning, degreasing and surface activation, an dation is drawn up.
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Through the merger of the corporate groups OSBORN In the process, Lipprite® abrasive rollers represent an alterna-
International and Lippert-Unipol, we have been able to signif- tive to brush rollers in various applications. Besides finishing
icantly expand our range in the field of rollers for achieving a applications, they are used for working roll cleaning, for sur-
technical or optical surface finishing. face activation, as well as for de-scaling.
Overview of the roller coverings and material specifications for Lipprite® abrasive rollers
Aluminium oxide abrasive grain (AI2 O3) Silicon carbide abrasive (SiC)
The processing results achieved by Lipprite® abrasive rollers Based on many years of experience or by individual tests on
may vary a lot depending on the roller specifications, surface our test lines, we are able to specify the right product in a tar-
and individual usage parameters. For orientation, the follow- geted way for almost any surface roughness required.
ing approximate values for the achievable surface roughness Contact our application engineers.
(Rt) are:
• A4 (coarse) = 3.3 - 3.9 mm
• A6 (fine) = 2.9 - 3.6 mm
• A7 (very fine) = 1.1 - 1.8 mm
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Lipprite® abrasive rollers are manu- Technical data and product characteristics:
factured from abrasive non-woven
flaps through radial adhesion to a • max. roller width 2000mm
core. The abrasive grinding grain • max. roller diameter 450mm
made of silicon carbide (SiC) or alu- • Version available with or without impregnation
minium oxide (Al2O3) is at the same • Rollers are dynamically balanced in accordance with DIN
time, embedded into the surface of EN ISO 1940
the random web fibre non-woven
material (made of polyamide or other synthetic material) by Recommendations concerning the use of rollers:
means of resin. The corrosiveness of the roller is individually
determined by the density of the pressure, i.e. the number of • Use in wet or dry operations
flaps. • Optimum cutting speed 15-25m/s
• Line (strip) speed or feed speed up to 30m/min. (max.)
An optional additional impregnation makes the roller even • Processing in the opposite direction to the running direction
more corrosive and increases the lifetime. It is necessary to of the material feed
bear in mind, however, that because of the significantly • Optimum depth of immersion 2-6mm, depending on the
increased hardness, impregnated rollers are less flexible. As roller diameter and hardness
such, surface undulations can be harder to balance, which • Oscillation improves the uniformity of the machining profile
may result in a less uniform finish or in terms of the machin-
ing profile, visual shading.
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Strip lines and rolling mills are equipped with a large number In parallel, through close cooperation with one of the world’s
of different rolls for completely different tasks and applica- leading manufacturers of technical non-woven materials,
tions. Through ever-higher line speeds and steadily increasing OSBORN has managed to develop a well-engineered series
demands in terms of quality and process reliability, the of products under the NOVOTEX® brand name, which are able
demands made on roll covers and surfaces also increases. As to fully satisfy the consumer’s expectations in terms of quali-
such, non-woven rollers, with their special material proper- ty, reliability, durability and an excellent price/performance
ties, become increasingly important within the steel, alumini- ratio.
um and non-ferrous metal industry.
OSBORN’s NOVOTEX® rollers are used where other synthetic • It is significantly easier to avoid aquaplaning effects
roller coatings reach their limits and can no longer ensure
optimum results or stable processes, as compared to rubber • Through the applied pressure of the random web with high
or polyurethane, non-woven material offers crucial advan- pressure on a roller core, a roll coating arises which, with a
tages. hardness of up to 95 shore A, exhibits an enormous resist-
ance to being cut as well as a ‘self-healing’ effect in the
• The porous structure of non-woven fabric in combination event of light cuts
with a large pore volume makes the material compressible
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Economic benefits
• Even with the aid of the non-woven roll, quality and process
improvements gained in manufacturing operations con- NOVOTEX® non-woven roll Conventional rubber roll
tribute to an increase in economic efficiency
Friction coefficient as a feature of the oil film for solvent based liquids
0,30
0,25
0,20
Friction coefficient
0,15
0,10
0,05
0,00
0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00 4,50 5,00 5,50 6,00 6,50
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Product range
Apart from non-woven fabric coverings our range of products shaft accessories. Users can benefit from our maintenance
includes the production of shafts as well as the recovering of service which includes the examination and repair of dam-
worn out rolls. We offer complete package systems specifical- aged rolls as well as accessory parts.
ly for the construction of lines including bearing units and
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Materials
When selecting the optimum non-woven fabric for the indi- Through the new development of the NOVOTEX® 12 covering
vidual application we can rely on the various material quali- material based on polypropylene, we have now also covered
ties which have been tried and tested and continuously squeezing applications in acidic cleaning and/or pickling sta-
improved over the years and which can be easily distin- tions using non-woven material.
guished by different colours.
Technical data
Basic fibre PA PA PA PP
Range of hardness 90-94 shore A 70-85 shore A 90-95 shore A 70-80 shore A
Applicable for liquid categories oil and emulsions oil and emulsions oil and emulsions acids, alkalines
water water solvents oil and emulsions
squezzing, pinching squezzing squezzing, driving squezzing
main applications breaking
Camber ground
The roll deflection is of crucial importance for an optimum For this reason, OSBORN International defines the optimal
and uniform squeezing result over the entire width of the feed force for each non-woven roll and on this basis, works
strip. This is especially the case in weak or undersized shaft out the expected roller deflection. The roll balling will be
constructions. When the feed is too high the roll ‘whips’ lead- ground to exhibit convex or concave contours.
ing to excessive residual moisture in the central area, while
too little feed force causes wet edges or border areas.
Force
Bending X/Y - level
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Applications
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Applicator rolls
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By connecting of a pair of squeezing rolls made from special nology, which has been proven and established in Japan for
micro fibre non-woven material with simple vacuum technol- decades, it is sometimes possible to dispense entirely with a
ogy, we are able to offer an innovative, energy-saving and fan or hot-air dryer. As a result, a single line can achieve annu-
with it, a particularly environmentally-friendly system for al energy savings of up to EUR 100.000.
strip drying in a variety of process lines. Through this tech-
Dry surfaces and very low energy consumption - without hot air
The function of the system is simple. The role vacuum gener- Significant quality or process-related optimisation has also been
ated on the perimeter sucks the liquid remaining on the strip created through the vacuum technology, with absolute dry strip
surface into the roll, supported by the capillary action of the edges being just one leading example. Media displacement
micro fibre non-woven covering. Through the hollow shaft on through the gap in the squeezing rollers in the edge area is elim-
its perimeter, which has numerous holes on it, send is then fed inated entirely by the strong vacuum function and the need for
again, via the vacuum pump, to the existing fluid circuit. subsequent expensive/laborious drying is dispensed with.
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The rolls function with a very soft surface and only minimal
contact pressure. As such, the coating is significantly less
prone to wear and essentially more resistant to damage from
strip edges than is the case with traditional squeezing rolls.
Without its own power, the limited in-feed of the roll pre-
serves the condition of the rolls, as well as the bearing and
the line itself. This creates a lifespan for the rolls averaging
four to five years (depending on individual application) with
only minimal maintenance. All that is needed is one trimming
session and follow-up grinding of the roll surface from time
to time.
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By linking our technological leadership in brush rollers with plant. Our focus primarily lies in swapping old machines
the competence and experience gained from teaming up with which no longer work optimally in existing lines, while at the
a whole range of line installers across the world we are, in same time optimising brush rollers and usage parameters in
cooperation with selected partners in the field of mechanical order to achieve sustainable quality and process improve-
engineering, in the position to offer well-engineered and indi- ments.
vidually adapted brushing machines and line concepts which
go further than the established standards of simple new
Along with this background, we are also able to offer a new, fully • Easy and precise positioning of the rollers through mechanical
patented machine package which includes a variety of innovative clamping
developments:
• As a result: optimum and consistent, reliable feeding of the brush
• A rigid machine housing which is heavily cushioned against rollers via the immersion depth by means of height adjustment
vibrations and protected against corrosion, made of a composite using precision lifting spindle elements with a servo positioning
stainless steel/mineral cast construction motor (parallelism tolerance approx. 0.1 mm)
• Compact and extremely dense OSBORN HDL® brush rollers enable • Replacement of the rollers without disassembling the bearing units
precise control of the depth of immersion
• Optical control at any time through side access doors with large win-
• Easier and quicker replacement of the rollers within a few minutes dows on the operator side and the interior lighting of the plant
using an insertion skid with no additional dismantling tools
• Non-contact measurement of the roller diameter in operation
• Compact design enabling the unit to require little space - only
1500 mm for each upper/lower brush for strip widths up of to approx. • Optional construction according to the brush/brush principle
2000 mm
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For many years, lines according to the Japanese design have • In all, the performance of the respective strip cleaning unit
enjoyed a technologically leading role. In recent years, we is significantly improved, and in turn this can contribute to
have able to successfully realise new line projects with improving the strip quality and an increase in the line
renowned steel producers in Europe, North America, Asia and speed.
Africa together with our Japanese partners, by adjusting the
components to international standards. • Acquisition and maintenance costs are correspondingly
reduced.
• With these lines, the brush/brush principle instead of the
conventional brush/back-up roll design brings a number of • Above all, when exchanging brush machines in existing strip
advantages with it. lines, valuable space for additional pre-cleaning sections
can be achieved alongside more intensive brushes.
• Due to the halving the amount of roll pairs which are
required, a 50% space saving is achieved. • The contact surfaces strip/upper brush and strip/lower brush
are identical. This reduces vibrations. Through gentler run-
• In the case of thin straps, the brush in the border area no ning of the strip brush shading and shatter marks on the
longer works on the back-up roll but combs in the opposite strip surface are avoided.
brush. Fully uniform wear of the brush balling is achieved in
the border area through the additional oscillation of the
rolls.
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Load Runners ®
6 Idler rollers and load rails
The name Load Runners® stands for five decades of experience Apart from an extensive standard program of over 300 arti-
in manufacturing of idler rolls and guidance systems for preci- cles in stock or available at short notice up to a diameter of
sion moving heavy loads in difficult conditions. Line builders 250mm, special sized rolls can also be tailor-made in small
and operators of rolling mills, strip lines or heat treatment quantities for special requirements.
plants trust in OSBORN’s coil, plate, tray and roller transport or
bearing equipment as well as the company’s automatic doors
and a whole host of applications based on this technology.
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Load Runners® idler rolls are tightly sealed and greased for
Types
their entire service live. As such they are insensitive to dirt,
Plain Stud Style moisture and extreme temperatures. Long-life maintenance-
· radial and thrust loads free operation ensures high levels of economy without main-
· easy to install tenance.
Plain Yoke Style The precision tapered roll bearings and grooved ball bearings
· radial and thrust loads used are particularly suitable for both radial and axial loads
· higher capacity than stud style
and can even be used at high speeds. This ensures key advan-
Flanged Stud Style tages over conventional needle bearings.
· radial and thrust loads
· easy to install Precision adjusted and hardened guiding rails made of high-
duty alloy steel are extremely resilient, wear resistant and
Flanged Eccentric Stud Style
free from twist effects. As such, heavy loads can be moved
· radial and thrust loads
precisely and reliably.
· easy to install
· vertical adjustment
Cam Runner
· composite outer
· stainless steel shaft
· wet environments
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Fill materials
7
Novofil NM
Novofil NN
Novofil NH
Novofil HR
Novofil PR
Novofil PT
Novofil TR
Material group PA 6 PA 6.6 PA 6.12 PA Special PP PBT
Temperature resistance
Permanent (°C) 90 90 90 95 190 70 100
Max. short-term (°C) 120 120 120 120 250 100 130
Water absorption
(at 23°C) 10% 8% 3% 9% 7,50% <1% <0,5%
Mechanical properties
Bend recovery + + + + + 0 -
Stiffness - 0 + - 0 + +
Resistance to abrsion + + + + 0 0 -
Chemical resistance
Against alkalines + + + + + 0 0
Against acids - - 0 - + + +
Novofil NN-S
Novofil NA-A
Novofil NH-S
Novofil NH-C
Novofil NA-S
Novofil HR-A
Novofil HR-S
Novofil NL-A
Novofil NL-S
Material PA 6.12 PA 6.12 PA 6 PA 6 PA 6.12 PA 6.12 PA 6.12 PA 6.12 PA 6.12 PA 6.12 PA 6.12
Abrasive Material SiC Al2O3 SiC Al2O3 SiC Al2O3 SiC Al2O3 Al2O3 SiC Al2O3
Grit size 46-1000 80-1000 46-500 60-500 46-500 80-500 46-320 120-320 80-320 46-500 46-500
Density (g/cm3) 1,3 1,5 1,3 1,5 1,3 1,5 1,3 1,5 1,65
Temperature resistance
Permanent (°C) 90 90 90 90 95 95 90 90 90 80 80
Max. short-term (°C) 120 120 120 120 130 130 120 120 120 110 110
Water absorption
(at 23°C) 3% 3% 10% 10% 3% 3% 3% 3% 3% 1,50% 1,50%
Mechanical properties
Bend recovery + + 0 0 + + + + + 0 0
Stiffness + + 0 0 + + + + + 0 0
Resistance to abrasion + + 0 0 + + + + + + +
Chemical resistance
Against alkalines + + + + + + + + + 0 0
Against acids 0 0 - - - - - - - + +
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hoch temperatur-
hoch korrosions-
Phosphor-Bronze
Edelstahldraht
Edelstahldraht
Bessemer Wire
CD Steelwire
AB Steelwire
Brass coated
beständiger
beständiger
Brasswire
Steelwire
Steelwire
Steelwire
Cordwire
Stainless
Draht
Material group Carbon Steel Steel Steel Steel 1.4301 1.4401 Special Brass Steel Phosphor
steel legiert hochlegiert brass coated brass coated 1.4541 1.4571 soft Bronze
Type crimped crimped crimped crimpedcrimped crimped crimped crimped crimped crimpedcrimped
Density (g/cm3) 7,85 7,85 7,85 7,85 7,85 7,90 8,00 8,00 8,30 7,80 8,90
Temperature resistance
Permanent (°C) 300 300 300 300 300 620 500 1150 170 250 170
Wear properties
Elasticity modul (kN/mm2) 210 210 210 210 210 195 195 195 80 200 110
Zugfestigkeit (N/mm2) 1900 2100 2400 2300 1900 1800 1800 1600 900 700-1200 1000-1300
Hardness (Knopp) 480 500 630 530 530 370 400 160 200 330
Fatique resistance - 0 + + + 0 - + - - 0
Erosion performance - 0 + + + 0 - 0 - - -
Chemical resistance
Against alkalines - - - 0 0 + + + + - +
Against acids - - - - - 0 + + - - 0
Application nedium mittelschwer heavy medium heavy medium medium medium light light mittelleicht
Novofil MY-S
Novofil MX
Novofil MY
Horse hair
Tampico
Material group not abrasive abrasive Filament Material group Animal hair Natural fibre
abrasive mixture
Abrasive material - Al2O3 SiC SiC/Al2O3 Properties - very soft bristle - very good tem-
with low static perature resi-
Properties Micro-fibre multifilaments ae usu- charging and stance as well as
ally manufactured with high den- excellent sealing electric conducti-
sities into special OSBORN HDL® effect vity
brush constructions. - suitable for care- - used for dedu-
ful cleaning of sting, light clea-
The filament selection and specifi- extremely sensi- ning and to apply
cation will be defined and custo- tive surfaces, to polishing emul-
mized to the specific application. apply liquids or sions
for brush sea-
Our application engineers are glad lings
to be further assistance.
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Technical information
8
An optimal brush result is determined by different parame- surface speed, brush speed as well as depth of immersion
ters. After selecting the appropriate bristle as well as the and contact pressure have to be taken into account, and
brush design to be used, determining the fill density and individually defined under the given framework.
trim length in the process, the focus then turns to the cor-
rect operational parameters. In addition, criteria such as
100,00
80,00
Kissmark (mm)
60,00
40,00
20,00
0,00
0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00 4,50 5,00 5,50 6,00 6,50
Depth of immersion (mm)
2000
Rpm (min-1)
1500
1000
500
0,00
Dedusting (10 m/sec) Cleaning (13 M/sec) Work roll cleaning (15 m/sec) Descaling (18 m/sec)
Different applications and fill materials require wholly dif- The tables in this section should provide approximate val-
ferent speeds. In turn, the appropriate speed depends on ues and indications. For detailed information and individual
the roll diameter. recommendations, please consult our application engi-
On the other hand, the optimum contact pressure can vary neers who will be happy to help.
greatly according to the brush construction and the fill den-
sity. The decisive factor in achieving the required brush
result is the immersion depth, as a brush tool works prima-
rily with the bristles and/or the tips of the wire.
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Terminology
44
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www.loadrunners.de
OSBORN TOP
High performance power brushes - Superior range for demanding applica-
tions and intense production conditions in industry.
www.top-brush.com
OSBORN Novofil®
Abrasive nylon brushes in Hi Tec filaments, rectangular and round in
Diamond, Zirconium, Aluminium Oxide and Silicon Carbide. Available in a
wide range of grit values.
OSBORN MultiStrip®
Saving thermal energy, reducing the passage of sound, protecting against
insect and vermin infestation, sealing against dust, dirt, water and smoke,
cleaning of industrial and commercial conveying systems.
www.multistrip.de
www.microabrasive-brush.com
45
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www.pipelinebrush.com
OSBORN ATB®
ATB - Advanced Technology Brush System!
Disc brushes with abrasive high-tech filaments. ATB disc brushes have fill
density which is 4 times higher than other disc brushes manufactured accor-
ding to the conventional method (punched).
OSBORN Novoflex-B®
The flexible honing tool!
www.lippert-unipol.de
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Brazil • China • Denmark • France • Germany • Great Britain • India • Mexico • Portugal • Romania • Spain • Sweden • USA
03/09
2033 GB
Subject to alterations.
OSBORN International GmbH · Manufacturer of Industrial Brushes, Surface Finishing Tools and Load Runners
Ringstraße 10 · 35099 Burgwald-Germany · Phone: +49 (0) 64 51 / 5 88-0 · Fax: +49 (0) 64 51 / 5 88-208
eMail: techsales@osborn.de · www.osborn.de · www.metallurgy-brush.com