Mechanical high speed roll changing system for use with a robotic roll changing system

Abstract

The present invention relates to a roller mounting system comprising a roller assembly (200) coupled to one or more rollers (201). The roller assembly (200) is configured to position the one or more rollers (201) for mounting or dismounting the one or more rollers (201) using a taper assembly (204). Moreover, the roller mounting system comprises a torque assembly (208) coupled to the roller assembly (200). The torque assembly (208) is configured to provide torque to the roller assembly (200) for mounting or dismounting the one or more rollers (201).

Description

Background Technology

[0001] This invention relates to the field of wire rod rolling using cantilever mill stands. Currently, rolls are changed manually by operators, either due to quality-related issues or when the mill requires roll replacement due to wear or when a different product size needs to be produced. The average manual changeover time per stand is around 20 minutes; the most experienced operators can change stands in 12 minutes. Rolls with sleeves can weigh up to approximately 31 kg, and in some cases the high-pressure hydraulic tools used for installing and removing rolls are even larger. The weight exceeds permissible lifting limits and must be lifted from cranes and / or robotic arms, further complicating the roll-changing process. Of course, there are risks of injury from entanglement and burns from hot equipment when changing rolls on the machine. Summary of the Invention

[0002] According to one aspect of the invention, a roller mounting system is provided. The roller mounting system includes a roller assembly coupled to one or more rollers, wherein the roller assembly is configured to use a tapered component to position the one or more rollers for mounting or dismounting the one or more rollers. Furthermore, the roller mounting system includes a torque component coupled to the roller assembly, wherein the torque component is configured to provide torque to the roller assembly for mounting or dismounting the one or more rollers.

[0003] According to another aspect of the invention, a method for performing operations of a roller mounting system is provided. The method includes positioning one or more rollers into a roller assembly. The roller assembly is configured to use a tapered component to position the one or more rollers for mounting or dismounting the one or more rollers. A torque component is configured to provide torque to the roller assembly for mounting or dismounting the one or more rollers. Attached Figure Description

[0004] Figure 1A-1B These are schematic diagrams illustrating different views of a roller housing without roller assemblies according to some embodiments;

[0005] Figure 2A-2B This is a schematic diagram of a roller assembly to be used in a roller mounting system according to some embodiments;

[0006] Figures 3A-3B This is a schematic diagram of a roller housing having a roller assembly installed for use in a roller mounting system, according to some embodiments;

[0007] Figures 4A-4B This is a schematic diagram of a roller housing having one roller assembly to be installed, and a roller housing having two roller assemblies installed by a roller mounting system, according to some embodiments.

[0008] Figures 5A-5BThis is a schematic diagram of a roller assembly tool according to some embodiments for installing or removing roller assemblies in a roller mounting system;

[0009] Figures 6A-6B This is a schematic diagram of a roller assembly tool together with roller components in a roller mounting system according to some embodiments;

[0010] Figure 7 This is a schematic diagram of a roller housing according to some embodiments, the roller housing having a mounted roller assembly and a roller assembly tool in a roller mounting system together with the roller assembly;

[0011] Figures 8A-8B This is a schematic diagram of a roller housing according to some embodiments, the roller housing having a mounted roller assembly and a roller assembly tool in a roller mounting system together with the roller assembly;

[0012] Figure 9 This is a schematic diagram of a possible overall arrangement of a roller housing with a roller mounting system on a robot, according to some embodiments; and

[0013] Figure 10 This is a schematic diagram of a possible overall arrangement of a roller housing with a roller mounting system on a robot, according to some embodiments. Detailed Implementation

[0014] This disclosure describes a mechanical roll changing system for use with a robot or otherwise assisted roll changing system. This disclosure addresses the problems associated with mechanical roll changing on cantilever mill stands. The use of high-pressure hydraulic devices is eliminated, thereby reducing the weight and complexity of the tooling system. Furthermore, in some embodiments, multiple tools (i.e., roll handling tools, roll mounting tools, and roll removal tools) are not required. With the new roll mounting and dismounting system capable of being integrated as an end effector into commercial robots or 6-axis robots, manual removal and mounting of rolls is no longer necessary. Roll changing can now be automated. In some embodiments, the novel roll mounting arrangement eliminates the problem of part failure and increases the load-bearing capacity of the mill stand.

[0015] The roller mounting system includes a roller, a spring, a tapered sleeve, a tapered sleeve remover and torque isolation ring, and a locking / unlocking nut. To mount the roller using this system, a robot or arm equipped with the attached roller mounting system presents the roller assembly, as described below, to a pinion. Once correctly positioned, the roller mounting system drives the locking and unlocking nuts in the correct direction via a torque driver to push the tapered sleeve between the roller and the pinion, thus tightening the tapered sleeve to generate the correct amount of force to hold the roller in place. The applied torque is isolated by the tapered sleeve remover and torque isolation ring, which are integral parts of the roller assembly and dock with the roller mounting system to prevent any torque load from being transmitted to the robot arm during operation via the roller mounting system.

[0016] Figure 1A This is a schematic perspective view of a roller housing 100, which has the main components of a roller housing structure 110 and a roller pinion 120. The housing structure includes a front plate 101 and a retaining ring 102.

[0017] Figure 1B This is a schematic cross-sectional view of the roller housing 100, showing the internal arrangement of the roller pinion 120 within the roller housing. Key features of the roller pinion are the tapered region 121 and the threaded region 122.

[0018] Figure 2A This is a schematic perspective view of a roller assembly 200, which has the following main components: a grooved roller 201 for forming a hot metal workpiece, a spring 202, a tapered sleeve 204, a tapered sleeve removal and torque isolation ring 206, and a locking / unlocking nut 208. The tapered sleeve removal and torque isolation ring 206 includes a splined area for engaging with a combination tool. The locking / unlocking nut 208 includes a recessed cavity for engaging with the combination tool to supply torque to the nut 208.

[0019] Figure 2B This is a schematic cross-sectional view of the roller assembly 200, showing the internal arrangement of the assembly. Key features of this arrangement include: a spring 202 between the tapered sleeve 204 and the roller 201, the spring functioning to hold the roller 201 against a retaining ring on the roller housing before the tapered sleeve 204 fully engages with the roller pinion; a tapered portion on the tapered sleeve 204 that matches the cone angle of the roller pinion; splines on the tapered sleeve 204 that engage with matching splines on the roller pinion; splines on the tapered sleeve removal and torque isolation ring 206 that engage with matching splines in a special tool; and internal threads on the locking / unlocking nut 208 that engage with matching threads on the end of the roller pinion.

[0020] In some embodiments, the tapered sleeve includes a taper angle in the range of 6-12 degrees to allow for the use of lower forces during roller removal. The tapered sleeve is an integrated component of a larger system rather than a separate part.

[0021] Another aspect is the significant improvement in the tapered sleeve design. The new sleeve has a steeper angle on the surface that mates with the roller pinion. This steeper angle results in less sliding wear on both the sleeve and the pinion. The steeper angle is primarily due to the new system maintaining a constant axial force on the sleeve imposed by the lock nut. The system with a shallower angle relies on the roller installation tool to forcefully push the sleeve onto the pinion, thereby tightening the sleeve and thus radially pushing the roller, using the resulting friction to provide torque-carrying capacity to the frame. The force used for installation needs to be limited because the same sleeve must be pulled off the pinion during roller changes.

[0022] During removal, there is a high risk of the "ear" of the tapered sleeve breaking due to the application of large removal forces. The current sleeve design is bayonet-type, meaning the ear that engages with the removal tool is less than 180° around the sleeve circumference. The new sleeve with a steeper angle can be installed with greater force (imposed by the lock nut), followed by continuously increasing force after installation, as the lock nut remains in place. During removal, the portion of the tapered sleeve to which the removal force is applied is a continuous loop around the sleeve's periphery, thus distributing the force and significantly reducing the risk of breakage. Furthermore, because a larger force can be applied to the tapered sleeve, the frame's torque capacity is increased due to the increased tension of the sleeve relative to the roller.

[0023] Figure 3A This is a schematic perspective view of a roller housing 300 having roller assemblies 302 attached to each of the roller pinions 120, illustrating how the grooves in the rollers are aligned such that a metal workpiece forms the shape of a groove as it passes between the rollers.

[0024] Figure 3B It is a schematic cross-sectional view of a roller housing 300 having roller assemblies 302 each mounted to roller pinions 120, showing the internal arrangement of the roller housing and roller assemblies. Figure 3B The most obvious and important features are: the contact between the roller and the retaining ring on the housing 300, which are forced into contact by the spring 202; and the engagement of the tapered sleeve 204 with the tapered area of ​​the roller pinion 120.

[0025] Figure 4A This is a schematic perspective view of a roll housing 400, in which the axis of rotation of the roll pinion 402 is oriented at approximately a 45° angle from a horizontal line as is typically used in rolling mills. The roll housing has no attached roll assemblies, but has a roll assembly 404 coaxially oriented with one of the roll pinions 402, just as it would have been before the roll assembly 404 was mounted onto the roll pinion 402.

[0026] Figure 4BThis is a schematic perspective view of a roll housing 400, in which the axis of rotation of the roll pinion 402 is oriented at approximately a 45° angle from a horizontal line as is commonly used in rolling mills, and the roll housing has a roll assembly 404 attached to the roll pinion 402.

[0027] Figure 5A This is a schematic perspective view of a roller assembly tool 500 for installing and removing roller assemblies from roller pinions, without the roller assemblies themselves. The roller assembly tool 500 includes a roller assembly retainer 502 coupled to the roller assembly. The roller assembly tool 500 includes a power wrench 504 for supplying torque. The power wrench 504 engages with the locking / unlocking nut 208 of FIG. 2. The roller assembly tool 500 includes devices for performing the following operations: when the locking / unlocking nut 208 pushes the tapered sleeve 204 onto the pinion or releases the tapered sleeve 204 from the pinion during roller removal, the power wrench 504 is rotated to provide torque to the tapered sleeve removal and torque isolation ring 206, thereby isolating the robotic arm or manipulator from torque. The roller assembly is configured to be mounted onto the corresponding roller pinion.

[0028] A roll holding mechanism 506 is attached to the tool holder 502 and provides support for the roll assembly when it is picked up by the roll assembly tool 500. A tapered sleeve holding mechanism 508 is attached to the assembly tool 502 and provides support for the tapered sleeve 204 when it is picked up by the roll assembly tool 500. A locking / unlocking nut 208 is configured to push the tapered sleeve 204 onto a pinion when it is introduced into the rolling shaft. A tubular or other structure 510 is coupled to the roll tool holder 502. The tubular or other structure 510 is coupled to a mounting flange 512. The mounting flange 512 can be connected to a robotic arm, etc.

[0029] Figure 5B This is a schematic cross-sectional view of a roller assembly tool 500 for installing and removing roller assemblies from roller pinions. The roller assembly tool does not have roller assemblies. The figure shows a mounting flange 512 for connection to a robot, a tapered sleeve retaining mechanism 508, a roller retaining mechanism 506, and a power wrench 504.

[0030] Figure 6A Is it like this? Figures 5A-5B The schematic perspective view shown is of a roller assembly tool 600 for installing and removing roller assemblies from roller pinions, the roller assembly tool having roller assembly 602.

[0031] Figure 6BThis is a schematic cross-sectional view of a roller assembly tool 600 for installing and removing roller assemblies from roller pinions, the tool having a roller assembly 602. The roller assembly tool 600 includes a mounting flange 604 for connection to a robotic arm, etc. A tapered sleeve retaining mechanism 606 contacts a tapered sleeve 608 in the roller assembly 602. A roller retaining mechanism 610 supports the roller in the roller assembly 602, and a power wrench 612 engages with a locking and unlocking nut 614 in the roller assembly 602.

[0032] Figure 7 This is a schematic perspective view of a roll housing 700, in which the axes of rotation of the roll pinions 704 and 710 are oriented at approximately a 45° angle from a horizontal line, as is typically used in rolling mills. The roll housing has a roll assembly 702 attached to the roll pinion 704 and a roll assembly tool 706 that holds the roll assembly 708 coaxially oriented with one of the roll pinions, just before the roll assembly 708 is mounted onto the roll pinion 710. The roll assembly tool 706 is similar to... Figures 5A-5B and Figures 6A-6B The roller combination tools 500 and 600 described herein.

[0033] Figure 8A This is a schematic diagram of a roll housing 800, in which the rotation axes of the roll pinions 802, 804 are oriented at approximately a 45° angle from a horizontal line typically used in rolling mills. The roll housing has a roll assembly tool 808 that holds a roll assembly 810 coaxially positioned with one of the roll pinions 804, as when mounting the roll assembly 810 onto or preparing to remove it from the roll pinion 804. The roll assembly tool 808 includes a mounting flange 812 for attachment to a robotic arm or lifting tool. Furthermore, the roll assembly tool 808 is similar to... Figures 5A-5B and Figures 6A-6B The roller combination tools 500 and 600 described herein.

[0034] Figure 8B This is a schematic cross-sectional view of a roll housing 800, in which the rotation axes of the roll pinions 802, 804 are oriented at approximately a 45° angle from a horizontal line as is commonly used in rolling mills. The roll housing has a roll assembly tool 808 that holds a roll assembly 810 coaxially positioned with one of the roll pinions 804, as if the roll assembly 810 were being mounted onto the roll pinion 804 or in preparation for removal from the roll pinion 804.

[0035] Figure 9This is a schematic perspective view of the roll housing 900 of a rolling mill, in which the rotation axes of the roll pinions 902, 904 are oriented at approximately a 45° angle from a horizontal line typically used in rolling mills. According to some embodiments, the roll housing has a roll assembly 908 held by a roll assembly tool 906, just as it would be before mounting the roll assembly 908 onto the intended roll pinion 904 using a mounting flange 910 connected to a robotic arm or lifting tool 912. Furthermore, the roll assembly tool 906 is similar to... Figures 5A-5B and Figures 6A-6B The roller combination tools 500 and 600 described herein.

[0036] Figure 10 This is a schematic perspective view of the roll housing 1000 of a rolling mill, wherein the rotation axes of the roll pinions 1002, 1004 are oriented at approximately a 45° angle from a horizontal line typically used in rolling mills. According to some embodiments, the roll housing has a roll assembly 1006 held by a roll assembly tool 1008, just as it would be before being mounted onto the intended roll pinion 1004. Furthermore, the roll assembly tool 1008 is similar to... Figures 5A-5B and Figures 6A-6B The roller combination tools 500 and 600 described herein.

[0037] To achieve a fully automated system, the roll mounting system requires installing new pinions onto the mill stand. However, existing pinions and any spare pinions in stock can be modified, refurbished, and used. This invention can operate without altering the existing mill inventory, but improvements can be made to roll inventory and scheduling by including RFID tags to communicate any changes to roll inventory and scheduling to the robotic system.

[0038] This invention simplifies existing roller handling, installation, and removal using a novel roller mounting system. The novel roller mounting system utilizes a tapered sleeve assembly, which allows for easier installation and removal despite the significant increase in size and weight. In some embodiments, the tapered sleeve assembly can withstand a maximum force of 98.8 mton. The increased force on the tapered sleeve increases the torque capacity of the roller assembly. The increased taper angle of the tapered sleeve also increases the service life of the tapered sleeve assembly due to less sliding wear. Furthermore, this invention does not necessarily require the use of hydraulic systems.

[0039] Although the invention has been shown and described with respect to several preferred embodiments, various changes, omissions and additions may be made therein in form and detail without departing from the spirit and scope of the invention.

Claims

1. A roller mounting system for mounting a roller assembly (200) to and removing a roller assembly (200) from a roller pinion (120) arranged in a roller housing (100), the roller mounting system comprising a roller assembly (200) and a roller assembly tool (500). The roller assembly (200) has a grooved roller (201) for forming hot metal workpieces, a spring (202), a tapered sleeve (204), a tapered sleeve removal and torque isolation ring (206), and a locking / unlocking nut (208). A spring (202) is arranged between the tapered sleeve (204) and the grooved roller (201) and its function is to press the grooved roller (201) against the guard ring (102) on the roller housing (100) before the tapered sleeve (204) and the roller pinion (120) are fully engaged during the installation of the roller assembly (200) to the roller pinion (120). The tapered sleeve (204) has splines that engage with matching splines on the roller pinion (120). The locking / unlocking nuts (208) have internal threads that engage with matching threads on the end of the roller pinion (120). The tapered sleeve removal and torque isolation ring (206) has a spline that engages with a matching spline in the roller assembly tool (500). The roller assembly tool (500) includes a roller assembly retainer (502) coupled to the roller assembly (200), a roller retaining mechanism (506) attached to the roller assembly retainer (502) for providing support to the roller assembly (200) when picked up by the roller assembly tool (500), and a tapered sleeve retaining mechanism (508) attached to the roller assembly retainer (502) for providing support to the tapered sleeve (204) when picked up by the roller assembly tool (500). The roller assembly tool (500) also includes a power wrench (504) and a device for performing the following operations: turning the power wrench (504) to provide torque to the locking / unlocking nut (208) for pushing the tapered sleeve (204) onto or off the roller pinion (120), thereby preventing any torque load from being transmitted to the robotic arm during operation when the robotic arm is connected to the mounting flange (512) of the structure (510), which is coupled to the roller assembly retainer (502).

2. The roller mounting system according to claim 1, wherein, The tapered sleeve (204) includes a taper angle between 6 degrees and 12 degrees.

3. A method for mounting a roller assembly (200) of a roller mounting system according to claim 1 or 2 to a roller pinion (120), the method comprising: The roller assembly (200) is supported by a roller holding mechanism (506) of a roller assembly holder (502) attached to the roller assembly tool (500). The roller assembly (200) is presented to the roller pinion (120) by a robotic arm attached to the roller assembly tool (500), thereby positioning the roller assembly (200) and the roller pinion (120) coaxially; Engage the power wrench (504) of the roller assembly tool (500) with the locking / unlocking nut (208) of the roller assembly (200); Remove the tapered sleeve and engage the spline of the torque isolation ring (206) with the spline in the roller combination tool (500); The locking / unlocking nut (208) is driven by a power wrench (504) to push the tapered sleeve (204) onto the roller pinion (120).

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