Introduction: Overcoming Alignment Challenges in Silicon Slitting Lines

Between August 19 and 29, the RITEC technical team carried out a comprehensive alignment and optimization project for a silicon steel slitting line at the Saudi Transformer Company. The objective was to address alignment issues, stabilize hydraulic pressure, and enhance cutting accuracy — ensuring efficient production and superior material handling.

Day-by-Day Project Progress

August 19 – Initial Inspection

The team ran the production line briefly to identify existing problems. Several tools and materials were missing or inadequate, and the felt used required replacement with a softer wool felt for better performance.

A supplementary tool list was drafted to standardize future commissioning work.

August 20 – Preparation and Setup

Materials were purchased, and a center frame made of angle steel was fabricated. All tools were laid out for use, ensuring readiness for alignment work.

August 21 – Machine Leveling

After measuring machine levels, almost all units were found misaligned. Adjustments began, and representatives from Saudi Transformer Company inspected progress, expressing concern but confidence in RITEC’s solution.

August 22 – Leveling Adjustments

Using precision instruments and shims, the team began leveling each machine. The process proved complex, revealing one separator shaft too high to adjust, which required a redesign.

August 23 – Reworking the Tension Station

After grinding attempts failed to correct misalignment, the support for the separator roller was removed for machining to lower it by 10 mm. The slitting machine was successfully aligned by the end of the day.

August 24 – Progress Review

Company executives visited again. Despite extreme heat, they inspected the work. The knife holder and blades were set up, and a silicon steel coil was loaded for testing.

August 25 – Hydraulic Pressure Issues

Testing revealed uneven pressure at the tension station, leading to recoiling misalignment. The hydraulic valve was changed from a double to a single set, but pressure remained unstable. The solution involved adding spacers to balance the tension.

August 26 – Conveyor and Guide Roller Adjustments

High-speed testing (150 m/min) caused material curling due to roller height mismatches. Adjustments included removing rollers, adding felt layers, and preparing a new guide roller after discovering eccentricity in the old one.

August 27 – Guide Roller and Cylinder Optimization

A new guide roller was welded and installed. Adjustments were made to the conveyor level and tension station cylinder stroke by inserting 25 mm plates. However, a gap under the side guide mechanism caused material deviation — prompting immediate redesign work.

August 28 – Benchmarking and Fine-Tuning

The team examined another 1000 mm silicon steel slitting line, noting its compact design and ease of operation. Returning to their project, they narrowed the gap between side guide rollers and continued improving material strip accuracy, now within 0.09 mm.

August 29 – Final Alignment and Accuracy

The RITEC team successfully reduced slitting accuracy errors to within 0.08 mm, marking a major technical achievement. The final phase involved documenting adjustment suggestions and training engineers and operators for long-term stability.

Adjustment Recommendations

Optimize the Tension Station

Replace the 25 mm spacer with a 30 mm flat spacer and tighten all screws.

Lower the scraper plate height by removing unnecessary shims to reduce friction.

Consider adding a central cylinder to balance uneven pressure.

Test the pressure plate flatness and machine it if necessary.

Enhance Conveyor Traction

Add more felt layers on the feeding conveyor to improve friction and eliminate gaps beneath the side guide mechanism.

Reposition the Recoiler Separator Shaft

Move the shaft 30–50 mm forward to optimize alignment, though operation can continue temporarily without this modification.

Introduce Automation for Safety

Install a sensor above the pit to detect short material and automatically stop the line, preventing damage from mismatched speeds.

Results and Takeaways

This project showcased RITEC’s commitment to precision engineering and continuous improvement. Through meticulous alignment, mechanical adjustments, and operator training, the team successfully:

Corrected multiple machine-level inconsistencies

Achieved slitting accuracy within 0.05 mm

Improved tension stability and feed alignment

Established a standardized tool list for future projects

The outcome demonstrates that technical precision and teamwork are key to achieving operational excellence in silicon steel slitting lines.