A two-roll straightener roll quick replacement process

Abstract

The application discloses a kind of two-roll straightening machine straightening roll quick replacement process, comprising: stop and cut off equipment total power supply and hydraulic system power supply, adjust straightening machine to facilitate maintenance station;With quick release mode opens equipment protection structure, by auxiliary pusher device old straightening roll is smoothly removed;In new straightening roll axle both ends sleeve positioning sleeve, utilize positioning sleeve and installation base positioning hole accurate cooperation, new straightening roll is centered and placed in installation position;Remove positioning sleeve, restore shaft coupling connection;In the both ends of each straightening roll installation quick fastening buckle, rotate locking handle complete quick fastening;After completion, connect power supply no-load operation, confirm that roll system rotates smoothly.The application is through six standardization processes of safety preparation, quick release old roll, accurate positioning, quick roll installation, fastening verification and no-load trial operation, cooperates with special quick release protection structure, roll shaft positioning tool, hydraulic pusher device and quick fastening component to realize efficient replacement.

Description

Technical Field

[0001] This invention relates to the field of metallurgical machinery and equipment maintenance, and in particular to a quick replacement process for the straightening rollers of a two-roll straightener. Background Technology

[0002] Two-roll straighteners are core straightening equipment in metallurgical, profile, pipe, and bar processing production lines, and are widely used in key processes such as steel finishing and straightening. As working parts that directly contact the workpiece, straightening rollers are consumable parts and need to be disassembled, inspected, and replaced regularly according to production wear. Their replacement efficiency directly affects the production line's operating rate, equipment utilization rate, and overall capacity.

[0003] Currently, the replacement of straightening rollers in traditional two-roll straighteners generally adopts the conventional method of overall disassembly and protection, manual alignment, and individual bolt tightening, which has obvious defects in practical applications: The disassembly process is cumbersome and the replacement efficiency is low. Before replacement, a large number of auxiliary structures such as the protective frame and transmission end cover need to be removed as a whole. There is no dedicated quick-disassembly structure, and the manual operation steps are numerous and time-consuming, which seriously occupies the effective production time.

[0004] Installation and positioning rely on experience, and accuracy is difficult to guarantee. The parallelism of the upper and lower rollers and the coaxiality of the roller shaft are entirely adjusted by the operator's experience. There are no special positioning auxiliary tools, resulting in large alignment deviations and long adjustment times, which can easily lead to insufficient straightening accuracy and increased product defect rate.

[0005] The fastening method is outdated and unreliable. The traditional method of tightening bolts one by one is not only time-consuming, but also results in uneven force, which can easily lead to problems such as loose rollers, worn threads, and deformation of connection parts, affecting the stability of equipment operation.

[0006] The disassembly and assembly process is unsafe and can easily damage the equipment. It relies on manual prying and handling to disassemble and assemble the rollers. Without dedicated support and stable pushing devices, it is easy to cause roller collisions and damage to bearing seats, and there are also significant operational safety hazards. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a quick replacement process for the straightening rollers of a two-roll straightener.

[0008] To solve the above technical problems, the technical solution of the present invention is as follows: A quick-change process for straightening rollers in a two-roll straightener specifically includes the following steps: S1. Stop the machine and disconnect the main power supply and hydraulic system power supply. Hang safety warning signs. Move the straightening machine to a position that is convenient for maintenance. S2. Use a quick-release method to open the equipment's protective structure and use an auxiliary jacking device to smoothly remove the old straightening roller; S3. Install positioning sleeves on both ends of the new straightening roller shaft, lift the new roller to the installation position, and use the positioning sleeves to precisely match the positioning holes of the installation base to center and place the new straightening roller in the installation position; S4. Apply high-temperature grease evenly to the mating surfaces of the new straightening roller shaft and bearing housing, gently push the roller shaft to make it fully fit, remove the positioning sleeve, and restore the coupling connection. S5. Install quick-fastening buckles at both ends of each straightening roller, rotate the locking handle to complete the quick fastening, check the locking torque and confirm that there are no gaps or looseness in each part; S6. After installation, connect the power supply and run it under no-load to confirm that the roller system rotates smoothly without jamming, abnormal noise, or vibration.

[0009] This invention provides a standardized replacement process to replace traditional, cumbersome operations, making the disassembly and assembly steps clear and replicable. It is also equipped with four special components: quick-release protection, positioning fixtures, hydraulic jacking, and quick fastening, to achieve overall speed up replacement, accurate positioning, reliable fastening, and stable operation.

[0010] In a further preferred embodiment of the present invention, S1 specifically comprises: Stop the machine and disconnect the main power and hydraulic system power of the two-roll straightener. Hang a safety warning sign that reads "Equipment under maintenance, do not turn on the switch" on the equipment operation panel to ensure that there is no risk of accidental start-up. Move the straightener to the maintenance position. Adjust the upper and lower straightening rollers to the maximum distance through the equipment's own hydraulic system so that the roller system is in a horizontal and stress-free disassembly position. Prepare specialized tooling and accessories, including a quick-release wrench for the two-roller straightener, a roller precision positioning sleeve, a quick-fastening buckle, a small hydraulic jacking device, a roller support hanger, high-temperature grease, and seals. At the same time, check the dimensional accuracy of the straightening roller to be replaced to ensure that it matches the equipment. Clean the iron filings, oil stains and debris from the mounting base, bearing seats and roller shaft connection parts of the straightener roller system. Check the integrity of the mounting base positioning holes and bearing seats to ensure there is no deformation or excessive wear, so as to avoid affecting the subsequent positioning accuracy.

[0011] In a further preferred embodiment of the present invention, S2 specifically includes: Using a special quick-release wrench, open the quick-release buckle of the straightener's protective device. There is no need to remove the entire protective frame; simply open the inspection port and remove the coupling pins connecting the upper and lower straightening rollers to the transmission end to disconnect the transmission connection. Small hydraulic jacking devices are symmetrically installed at both ends of the roller shaft. The jacking devices are fixed on the mounting base. The hydraulic jacking devices are started and the roller shaft is slowly pushed to separate the old straightening roller from the bearing housing and the mounting base. Use roller support lifting devices to smoothly lift and remove the old straightening rollers from the equipment and place them in a designated protective area to prevent damage from collisions. At the same time, clean the bearing housings and the positioning holes of the mounting base to remove any remaining debris.

[0012] In a further preferred embodiment of the present invention, the thrust of the hydraulic jacking device in S2 is 2-3t, and the roller shaft is kept horizontal during the jacking process.

[0013] In a further preferred embodiment of the present invention, one end of the positioning sleeve in S3 is interference-fitted with the roller shaft, and the other end is clearance-fitted with the positioning hole of the mounting base, so as to achieve coaxial positioning of the roller shaft and the mounting base.

[0014] In a further preferred embodiment of the present invention: after the new straightening roller is placed in the installation position in S3, the levelness of the straightening roller is detected by a level instrument, and the position of the roller shaft is adjusted by the fine-tuning function of the positioning sleeve.

[0015] In a further preferred embodiment of the present invention, the parallelism deviation of the upper and lower straightening rollers after installation is no greater than 0.03 mm / m, and the coaxiality deviation of the coupling is ≤0.05 mm. Beneficial effects

[0016] This invention eliminates the cumbersome steps of traditional whole-machine protective disassembly, manual alignment based on experience, and individual bolt tightening, reducing the single replacement time from over 8 hours to 2 hours. This significantly shortens replacement time, reduces non-production operation time, and improves the effective operating time of the production line. The invention employs a standardized six-step process: safety preparation, quick removal of the old roller, precise positioning, rapid roller installation, tightening verification, and no-load trial run. Combined with a dedicated quick-release protective structure, roller positioning fixtures, hydraulic jacking device, and quick-tightening components, it achieves efficient replacement without removing the entire machine's protective covering. The positioning sleeve ensures precise positioning of the straightening rollers, with a parallelism deviation of ≤0.03mm / m between the upper and lower rollers, avoiding errors from manual alignment and effectively reducing the straightening defect rate of subsequent products, thus improving product processing accuracy. The hydraulic jacking device enables smooth disassembly and assembly of the rollers. The positioning sleeve prevents hard contact between the rollers and the mounting base, and the quick-tightening buckles distribute force evenly, reducing thread stripping and deformation of connection parts caused by repeated bolt disassembly. This effectively extends the service life of the straightening machine and its components, reducing equipment maintenance costs. Detailed Implementation

[0017] To make the content of this invention easier to understand, the invention will be further described in detail below based on specific embodiments. Example 1

[0018] This embodiment provides a quick replacement process for the straightening rollers of a two-roll straightener, specifically including the following steps: S1. Stop the machine and disconnect the main power supply and hydraulic system power supply of the two-roll straightener. Hang a safety warning sign that reads "Equipment under maintenance, do not turn on the switch" on the equipment operation panel to ensure that there is no risk of accidental start-up. Move the straightener to the maintenance position. Adjust the upper and lower straightening rollers to the maximum distance through the equipment's own hydraulic system so that the roller system is in a horizontal and stress-free disassembly position. Prepare special tooling and accessories: including a special quick-release wrench for the two-roller straightener, two roller shaft precision positioning sleeves (with clearance fit to the roller shaft, clearance error ≤0.05mm), four quick-fastening buckles, a small hydraulic jacking device (rated thrust 5t), roller shaft support hanger, high-temperature lubricating grease, and seals. At the same time, check the dimensional accuracy of the straightening roller to be replaced to ensure that it matches the equipment. Clean the iron filings, oil stains and debris from the mounting base, bearing seats and roller shaft connection parts of the straightener roller system. Check the integrity of the mounting base positioning holes and bearing seats to ensure there is no deformation or excessive wear, so as to avoid affecting the subsequent positioning accuracy. S2. Use a special quick-release wrench to open the quick-release buckle of the straightener's protective device. There is no need to remove the entire protective frame. Just open the inspection port and remove the coupling pins connecting the upper and lower straightening rollers to the transmission end to disconnect the transmission connection. Small hydraulic jacking devices are symmetrically installed at both ends of the roller shaft. The jacking devices are fixed on the mounting base. The hydraulic jacking devices are started, and the roller shaft is slowly pushed with a uniform thrust of 2-3t to separate the old straightening roller from the bearing seat and the mounting base. The roller shaft is kept horizontal throughout the process. Use the roller support lifting device to lift the old straightening roller smoothly and remove it from the equipment. Place it in the designated protective area to avoid collision damage to the roller. At the same time, clean the residual debris in the bearing housing and the positioning hole of the mounting base. S3. Place positioning sleeves on both ends of the roller shaft to be replaced with a new straightening roller. One end of the positioning sleeve is interference-fitted with the roller shaft, and the other end is clearance-fitted with the positioning hole of the mounting base to achieve the initial positioning of the roller shaft and the mounting base. Using a roller support hoist, the new straightening roller with the positioning sleeve is lifted to the installation position, so that the positioning sleeve is precisely aligned with the positioning hole of the mounting base, and then slowly lowered to ensure that both ends of the roller are coaxial with the bearing housing. A level is used to check the levelness of the straightening rollers, and the position of the roller shaft is adjusted using the fine-tuning function of the positioning sleeve to ensure that the parallelism deviation of the upper and lower straightening rollers is ≤0.03mm / m, thus achieving precise positioning. S4. Apply high-temperature grease evenly to the mating surfaces of the new straightening roller shaft and bearing housing to reduce frictional losses during subsequent operation and extend bearing life. Manually push the roller shaft gently to ensure that the new straightening roller is fully fitted with the bearing housing and mounting base, ensuring that the roller shaft is not misaligned or stuck. Then remove the positioning sleeves at both ends of the roller shaft to complete the initial installation of the new roller. Reconnect the upper and lower straightening rollers to the coupling at the drive end, insert the pin and fix it, check the coaxiality of the coupling to ensure that the deviation is ≤0.05mm, and avoid abnormal noise and vibration in subsequent operation; S5. Install two quick-fastening buckles at each end of each straightening roller. The buckles fit precisely with the slots of the mounting base. Quick fastening is achieved by rotating the locking handle. There is no need to tighten the bolts one by one. The fastening time for a single fastening is ≤1 minute. After tightening, use a torque wrench to check the locking torque of the buckle to ensure that the torque value meets the equipment technical requirements and to prevent the roller from loosening. At the same time, check the fit between the straightening roller and each connection part to confirm that there are no gaps or looseness. S6. Clean up the tools and debris in the equipment maintenance area, close the maintenance port of the protective device, and remove the safety warning signs from the equipment control panel. Connect the power supply to the straightening machine, set the equipment to the "no-load operation position", start the equipment, and run the upper and lower straightening rollers without load for 1-2 minutes. Observe the rotation of the roller system, whether the straightening rollers rotate smoothly, without jamming, abnormal noise, or obvious vibration, and confirm that the linkage between the transmission system and the roller system is good.

[0019] In addition to the above embodiments, the present invention may have other implementation methods; all technical solutions formed by equivalent substitution or equivalent transformation fall within the protection scope claimed by the present invention.

Claims

1. A quick-change process for straightening rollers in a two-roll straightener, characterized in that: Specifically, the following steps are included: S1. Stop the machine and disconnect the main power supply and hydraulic system power supply. Hang safety warning signs. Move the straightening machine to a position that is convenient for maintenance. S2. Use a quick-release method to open the equipment's protective structure, and use an auxiliary jacking device to smoothly remove the old straightening roller; S3. Install positioning sleeves on both ends of the new straightening roller shaft, hoist the new roller to the installation position, and use the positioning sleeves to precisely match the positioning holes of the installation base to center and place the new straightening roller in the installation position; S4. Apply high-temperature grease evenly to the mating surfaces of the new straightening roller shaft and bearing housing, gently push the roller shaft to make it fully fit, remove the positioning sleeve, and restore the coupling connection. S5. Install quick-fastening buckles at both ends of each straightening roller, rotate the locking handle to complete the quick fastening, check the locking torque and confirm that there are no gaps or looseness in each part; S6. After installation, connect the power supply and run it under no-load to confirm that the roller system rotates smoothly without jamming, abnormal noise, or vibration.

2. The quick-change process for straightening rollers in a two-roll straightener according to claim 1, characterized in that: Specifically, S1 is: Stop the machine and disconnect the main power and hydraulic system power of the two-roll straightener. Hang a safety warning sign that reads "Equipment under maintenance, do not turn on the switch" on the equipment operation panel to ensure that there is no risk of accidental start-up. Move the straightener to the maintenance position. Adjust the upper and lower straightening rollers to the maximum distance through the equipment's own hydraulic system so that the roller system is in a horizontal and stress-free disassembly position. Prepare specialized tooling and accessories, including a quick-release wrench for the two-roller straightener, a roller precision positioning sleeve, a quick-fastening buckle, a small hydraulic jacking device, a roller support hanger, high-temperature grease, and seals. At the same time, check the dimensional accuracy of the straightening roller to be replaced to ensure that it matches the equipment. Clean the iron filings, oil stains and debris from the mounting base, bearing seats and roller shaft connection parts of the straightener roller system. Check the integrity of the mounting base positioning holes and bearing seats to ensure there is no deformation or excessive wear, so as to avoid affecting the subsequent positioning accuracy.

3. The quick-change process for straightening rollers in a two-roll straightener according to claim 2, characterized in that: S2 specifically includes: Using a special quick-release wrench, open the quick-release buckle of the straightener's protective device. There is no need to remove the entire protective frame; simply open the inspection port and remove the coupling pins connecting the upper and lower straightening rollers to the transmission end to disconnect the transmission connection. Small hydraulic jacking devices are symmetrically installed at both ends of the roller shaft. The jacking devices are fixed on the mounting base. The hydraulic jacking devices are started and the roller shaft is slowly pushed to separate the old straightening roller from the bearing housing and the mounting base. Use roller support lifting devices to smoothly lift and remove the old straightening rollers from the equipment and place them in a designated protective area to prevent damage from collisions. At the same time, clean the bearing housings and the positioning holes of the mounting base to remove any remaining debris.

4. The quick-change process for straightening rollers in a two-roll straightener according to claim 3, characterized in that: The hydraulic jacking device in S2 has a thrust of 2-3t, and the roller shaft is kept horizontal during the jacking process.

5. The quick-change process for straightening rollers in a two-roll straightener according to claim 1, characterized in that: In S3, one end of the positioning sleeve is interference-fitted with the roller shaft, and the other end is clearance-fitted with the positioning hole of the mounting base, so as to achieve coaxial positioning of the roller shaft and the mounting base.

6. The quick-change process for straightening rollers in a two-roll straightener according to claim 1, characterized in that: In step S3, after the new straightening roller is placed in the installation position, a level is used to check the levelness of the straightening roller, and the position of the roller shaft is adjusted using the fine-tuning function of the positioning sleeve.

7. The quick-change process for straightening rollers in a two-roll straightener according to claim 6, characterized in that: After installation, the parallelism deviation of the upper and lower straightening rollers shall not exceed 0.03 mm / m, and the coaxiality deviation of the coupling shall be ≤0.05 mm.