Anti-deformation mechanism of measuring tension roller

Abstract

The utility model discloses a measure tension roll anti -deformation mechanism, including the measure tension roll roll body, the outer surface of measure tension roll roll body is provided with the heat conducting layer, the outside of heat conducting layer is sleeved with the reinforcing layer, the inside of reinforcing layer is provided with the reinforcing module, is used for reinforcing the intensity of measure tension roll roll body, the outside of reinforcing layer is sleeved with the outer rubber roll layer, the inner wall of outer rubber roll layer is seted up with the flow guide groove, the left and right sides of measure tension roll roll body all are provided with the bearing seat, one side of two bearing seats all is provided with the pivot, and the heat insulating piece is connected between two bearing seats and measure tension roll roll body, and the heat insulating piece is used for blocking the heat, through the outside alloy steel cross type support beam of measure tension roll, improves its hardness, and the flow guide groove in the inside of outer rubber roll layer is used for internal constant temperature water to enter, prevents its heat and causes the expansion too high, improves its life.

Description

Technical Field

[0001] This utility model relates to the technical field of anti-deformation mechanism for tension rollers, and in particular to an anti-deformation mechanism for tension rollers. Background Technology

[0002] Tension measuring rollers are key equipment in continuous production lines such as metallurgical rolling and strip processing. Their core function is to calculate tension in real time by detecting the radial pressure applied to the strip, thereby ensuring tension stability and product quality.

[0003] However, the existing tension measuring rollers have low hardness, which can cause them to bend over time. They also have low strength and are prone to deformation. In addition, they generate a lot of heat during operation, which can cause expansion and damage to the tension measuring rollers, affecting their service life and overall work efficiency. Utility Model Content

[0004] To overcome the problems of existing tension measuring rollers, which expand due to internal heat after prolonged use, causing damage, and their low hardness reducing their service life.

[0005] The technical solution of this utility model is as follows: a tension measuring roller anti-deformation mechanism, including a tension measuring roller body, a heat-conducting layer provided on the outer surface of the tension measuring roller body, a reinforcing layer sleeved on the outside of the heat-conducting layer, a reinforcing module provided inside the reinforcing layer for reinforcing the strength of the tension measuring roller body, an outer rubber roller layer sleeved on the outside of the reinforcing layer, a guide groove provided on the inner wall of the outer rubber roller layer, bearing seats provided on both the left and right sides of the tension measuring roller body, a rotating shaft provided on one side of each of the two bearing seats, and a heat insulation component connected between the two bearing seats and the tension measuring roller body, the heat insulation component being used to block heat.

[0006] Preferably, the surface of the heat-conducting layer is plated with hard chrome, which enhances thermal conductivity and reduces the risk of localized overheating.

[0007] Preferably, there are multiple guide channels arranged in a ring array, and the guide channels are spirally opened on the inner wall of the outer rubber roller layer to allow constant temperature water to pass through, thereby reducing thermal expansion.

[0008] Preferably, the heat insulation component includes a heat insulation pad made of ceramic fiber material, used to block the heat conduction during rolling to the bearing.

[0009] Preferably, the reinforcement module includes horizontal support beams, multiple horizontal support beams are arranged vertically, and vertical support beams are fixedly connected between the multiple horizontal support beams, and multiple vertical support beams are arranged in a horizontal array.

[0010] Preferably, multiple transverse support beams and multiple vertical support beams are arranged in a cross shape on the surface of the tension roll body, and both the transverse support beams and the vertical support beams are made of alloy steel.

[0011] Preferably, one end of the bearing housing is connected to a self-aligning ball bearing to reduce the skewness of the tension roll body installation.

[0012] The beneficial effects of this utility model are:

[0013] 1. The anti-deformation mechanism of the tension roller improves its bending stiffness, enhances its overall strength, and extends its service life through the reinforcement layer on the outer surface of the tension roller, the cross-shaped arrangement of the transverse and vertical support beams, and its alloy steel material.

[0014] 2. The anti-deformation mechanism of the tension roll uses a spiral guide groove opened inside the outer rubber roller layer on the outer surface of the tension roll to introduce 25°C constant temperature water for internal use, reducing thermal expansion. At the same time, ceramic fiber heat insulation gaskets are installed between the bearing seat and the roll body to block the heat conduction of rolling to the bearing and extend its service life. Attached Figure Description

[0015] Figure 1 The diagram shown is a schematic representation of the overall structure of the anti-deformation mechanism for the tension roller of this utility model.

[0016] Figure 2 The diagram shown is a schematic representation of the anti-deformation reinforcement layer structure of the tension roller of this utility model.

[0017] Figure 3 The diagram shown is a partial structural schematic of the anti-deformation outer shell of the tension measuring roller of this utility model.

[0018] Figure 4 This utility model is shown. Figure 3 A magnified schematic diagram of the three-dimensional structure at point A;

[0019] Figure 5 The diagram shown is a three-dimensional structural schematic of the tension roller reinforcement layer of this utility model.

[0020] Explanation of reference numerals in the attached drawings: 1. Outer rubber roller layer; 2. Tension roller body; 3. Bearing seat; 4. Rotating shaft; 5. Reinforcing layer; 6. Guide groove; 7. Heat insulation pad; 8. Horizontal support beam; 9. Vertical support beam; 10. Heat-conducting layer. Detailed Implementation

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0022] The working principle of the tension measuring roller: The tension measuring roller essentially achieves real-time monitoring and control of strip tension through mechanical decomposition and sensor conversion. First, the strip wraps around the roller surface at a specific wrap angle (usually 30°-150°), generating radial pressure (F) on the contact arc. The value of this pressure is determined by the mechanical relationship between tension (T) and wrap angle (α): F = 2Tsin(α / 2). This pressure is transmitted to the support bearing seats at both ends of the roller body, where it is captured by integrated high-precision sensors (such as piezomagnetic pressure heads or strain gauges). The weak pressure signal is converted into an electrical signal. Subsequently, the electrical signal is amplified and filtered (for example, a Wheatstone bridge circuit converts resistance changes into differential voltage), and then environmental interference is eliminated through a temperature compensation algorithm, finally outputting a standardized tension value.

[0023] The control system (such as a PLC / PID controller) compares the measured tension with the set value and dynamically adjusts the output torque of the drive motor: Anti-slip scenario: When tension fluctuation > 15%, the servo motor increases torque within 10ms to ensure roller-belt synchronization; Eccentricity compensation: Based on FFT spectrum analysis, periodic vibrations caused by installation deviations are eliminated; Thermal deformation suppression: The internal cooling system maintains roller temperature fluctuations ≤ ±2℃ to avoid measurement distortion caused by thermal expansion.

[0024] Key accuracy assurance relies on three major design features:

[0025] 1. Wrap Angle Optimization: The hydraulic swing arm dynamically adjusts the wrap angle (e.g., pressure uniformity is improved by 60% when >120°), compensating for the attenuation of the actual wrap angle due to wear / centrifugal force (80%-90% of the theoretical value); 2. Anti-interference Structure: Dual support bearings distribute the load (deformation reduced by 40%) + laser texture on the roller surface increases the coefficient of friction (μ≥0.25); 3. Intelligent Feedback: Embedded fiber optic grating sensors monitor micron-level deformation, combined with AI algorithms to pre-compensate for elastic deformation errors (e.g., the bounce equation h=S0+F / K). m (Correction of thickness deviation).

[0026] In summary, the tension measuring roll achieves precise tension control through a closed loop of mechanical decomposition, sensor conversion, and dynamic compensation, with an error that can be stabilized within ±1%, providing core process support for scenarios such as high-speed rolling (>800m / min) and precision processing of thin strips (δ<0.2mm).

[0027] The installation of the tension roller must be strictly carried out in accordance with mechanical assembly specifications. The core steps include:

[0028] I. Basic Preparation 1. Component Cleaning: After unpacking, use a special cleaning agent to remove rust-preventive oil and impurities from the bearing and roller surface. Pay special attention to cleaning the oil holes and blow them with high-pressure air to ensure they are unobstructed (residual impurities will cause measurement drift of ±5%). 2. Damage Inspection: Laser inspect the roller surface for wear (dimples > 0.1mm require repair) and verify the thickness of the bakelite thrust plate (replace immediately if < 80% of the design value). 3. Environmental Control: Humidity ≤ 60% and temperature 20±5℃ in the installation area, dustproof rating ISO 7.

[0029] II. Mechanical Assembly 1. Coaxial Positioning: The laser emitter (such as the D22 type) is leveled at 30cm from the baseline and calibrated by prism reflection to ensure that the deviation between the roller centerline and the rolling line is <0.1mm2; the double support bearings are installed in numerical order (the saddle lettering faces the transmission side), and the arrow on the inner ring end face is aligned with the direction of force; 2. Pressure Sensing Integration: The piezomagnetic sensor is embedded in the reserved cavity of the bearing seat, the signal cable is protected by a metal flexible tube, and the interface is sealed with silicone (IP67 level); 3. Angle Wrapping Mechanism Installation: The distance L between the upper guide roller and the measuring roller is set according to the formula L=R / tan(α / 2) (R is the roller radius, α=120°±5°), and the positioning pin is locked after the hydraulic swing arm is adjusted.

[0030] III. Accuracy Verification 1. Static Test: Manually rotate the roller 3 times, the resistance torque ≤0.5N·m and there is no jamming (if the deviation is too large, the bearing preload needs to be checked); the radial runout is measured with a dial indicator (tolerance ±0.02mm), and the parallelism of the roller surface is checked with a laser interferometer (<0.05mm / m); 2. Dynamic Calibration: Run unloaded for 10min, inject a step tension signal (e.g., 10N→50N) into the PID controller, and verify that the sensor response time is <20ms and the linear error is <1%FS; Hot Test: Run with cooling water (30L / min, 25℃) for 2h, and monitor the roller surface temperature rise with an infrared thermal imager ≤15℃.

[0031] IV. When the measured tension fluctuation exceeds the set value ±5% after low-speed (≤30m / min) belt threading verification during production: 1. Wrap angle readjustment: hydraulically fine-tune the position of the upper guide roller to make the actual wrap angle >110° (pressure uniformity improved by ≥40%); 2. Eccentricity compensation: analyze the roller rotation spectrum using FFT and embed a harmonic filtering algorithm in the control system.

[0032] V. Key Points: Coaxial positioning accuracy (laser calibration) + wrap angle optimization (α > 110°) + thermal management (ΔT ≤ 15℃) are the three core elements to ensure the long-term stability of the tension measuring roller.

[0033] Preventing tension roll malfunctions requires a systematic protection strategy focusing on four core aspects: sealing protection, thermal management, bearing maintenance, and accuracy calibration. Specific measures are as follows:

[0034] I. Three-level sealing structure to prevent contamination: The roller end adopts a double-lip skeleton oil seal + labyrinth sealing cover + negative pressure dust collection device (air volume ≥120m³ / h). 3 / h), blocking the emulsion from entering the bearing cavity (under the protection of lithium-based grease, the emulsification rate is reduced by 90%); regular air blowing dust removal: clean the roller surface oil and dust with 0.6MPa compressed air every shift to prevent the accumulation of impurities from causing a decrease in the coefficient of friction (maintain μ≥0.25).

[0035] II. Thermal Deformation Control Constant Temperature Cooling System: Cooling water at 25℃ (flow rate 30L / min) is introduced, and an infrared thermal imager monitors the roller surface temperature rise in real time to ensure it is ≤15℃, avoiding radial runout exceeding tolerance caused by thermal expansion (deformation <5μm when △T≤±2℃); Roll surface temperature uniformity optimization: The perforated roller structure allows the heat transfer oil to directly contact the working surface, and with the surface hard chrome plating (50-80μm), the temperature distribution uniformity is improved to ±0.5℃.

[0036] 3. Precision maintenance and accurate control of bearing preload: The preload of tapered roller bearings is strictly set at 120% of the design value (if it is 15% too tight, the friction torque will increase by 50%). Tighten the nut in three diagonal steps (1.5-2.2 Nm) using a torque wrench; Bearing life extension technology: During installation, rotate the inner ring 90° to avoid the original load area, and replenish high-temperature grease regularly (the amount replenished every 500 hours is 30% of the cavity volume).

[0037] IV. Dynamic accuracy assurance: Laser coaxial calibration: The combination of D22 laser emitter and D46 pentaprism calibrates the roller axis, controlling radial runout ≤0.02mm and parallelism deviation <0.05mm / m; FFT harmonic compensation: Real-time acquisition of roller rotation spectrum, embedding harmonic filtering algorithm to eliminate periodic vibration caused by installation eccentricity.

[0038] V. Roller Surface Repair and Reinforced Carbon Nanoparticle Polymer Online Repair: When the roller surface scratch depth is >0.1mm, a polymer composite material is used for filling (adhesion >20MPa), and the wear resistance of the repaired parts is 30% higher than that of the original parts without disassembly; Pre-wear monitoring: The laser rangefinder periodically detects the ellipticity of the roller surface (>0.05mm triggers an early warning), and the remaining life is predicted by combining AI algorithms.

[0039] Key Practice: After implementing the above measures, the downtime rate of tension roller failure on a certain production line decreased by 85%, and the average annual maintenance cost decreased by 40%. The core of prevention lies in: four-dimensional collaborative control of sealing reliability (level 3 protection) → thermal stability (△T≤15℃) → bearing health (preload ±5%) → dynamic compensation (laser + FFT).

[0040] Please see Figures 1-5This utility model provides an embodiment of a tension measuring roller anti-deformation mechanism, including a tension measuring roller body 2. A heat-conducting layer 10 is provided on the outer surface of the tension measuring roller body 2. A reinforcing layer 5 is sleeved on the outside of the heat-conducting layer 10. A reinforcing module is provided inside the reinforcing layer 5 to strengthen the tension measuring roller body 2. An outer rubber roller layer 1 is sleeved on the outside of the reinforcing layer 5. A guide groove 6 is opened on the inner wall of the outer rubber roller layer 1. Bearing seats 3 are provided on both the left and right sides of the tension measuring roller body 2. A self-aligning ball bearing is connected to one end of the bearing seat 3 to reduce the misalignment of the tension measuring roller body 2 during installation. A rotating shaft 4 is provided on one side of each of the two bearing seats 3. A heat insulation component is connected between the two bearing seats 3 and the tension measuring roller body 2 to block heat. The structure of the tension measuring roller body 2 is a prior art solution. Therefore, the applicant will not provide a detailed description of the structure and components of the tension measuring roller body 2 or their connection relationships.

[0041] The surface of the heat-conducting layer 10 is plated with hard chrome. The hard chrome plating enhances the thermal conductivity and reduces the risk of local overheating. The outer surface of the heat-conducting layer 10 on the surface of the tension roll body 2 is plated with hard chrome to enhance the thermal conductivity of the tension roll body 2 and reduce the risk of local overheating. There are multiple guide grooves 6 arranged in a ring array and spirally located on the inner wall of the outer rubber roll layer 1. They are used to introduce constant temperature water to reduce thermal expansion. The guide grooves 6 are spirally located inside the outer rubber roll layer 1. The flow rate of 25℃ constant temperature water is ≥30L / min. Combined with real-time monitoring by an infrared thermal imager, it is ensured that the temperature rise of the roll surface is ≤15℃ and the temperature distribution uniformity is ±0.5℃, reducing the radial runout caused by thermal expansion. The heat insulation component includes a heat insulation gasket 7. The heat insulation gasket 7 is made of ceramic fiber material and is used to block the heat conduction of rolling to the bearing. The heat insulation gasket 7 made of ceramic fiber material is used between the bearing seat 3 and the tension roll body 2 to block the heat conduction of rolling to the bearing and prevent overheating and damage.

[0042] The reinforcement module includes horizontal support beams 8, multiple horizontal support beams 8 arranged vertically, and vertical support beams 9 fixedly connected between the multiple horizontal support beams 8. Multiple vertical support beams 9 are arranged in a horizontal array. The multiple horizontal support beams 8 and multiple vertical support beams 9 are arranged in a cross shape on the surface of the tension roller body 2. Both the horizontal support beams 8 and the vertical support beams 9 are made of alloy steel. By arranging the horizontal support beams 8 and vertical support beams 9 in a cross shape on the outside of the tension roller body 2, the hardness is improved, the strength of the tension roller body 2 is strengthened, and bending is prevented due to long-term use, thereby increasing its hardness and extending its service life.

[0043] During operation, the outer surface of the tension roll body 2 is reinforced with a cross-shaped braided arrangement of transverse support beams 8 and vertical support beams 9. This increases the hardness and strength of the tension roll body 2, preventing bending during prolonged use and extending its service life. A spiral guide groove 6 is installed inside the outer rubber roller layer 1, through which 25℃ constant-temperature water with a flow rate ≥30L / min is introduced. Combined with real-time monitoring by an infrared thermal imager, this ensures that the roll surface temperature rise is ≤15℃ and the temperature distribution uniformity is ±0.5℃, reducing radial runout caused by thermal expansion. A ceramic fiber insulation pad 7 is used between the bearing housing 3 and the tension roll body 2 to block the conduction of rolling heat to the bearing, preventing overheating and damage.

[0044] Through the above steps, the reinforcement layer 5 on the outer surface of the tension roll body 2, the cross-shaped arrangement of the transverse support beam 8 and the vertical support beam 9, and the alloy steel material, the bending stiffness is improved, the overall strength is increased, and the service life is extended. This solves the problem that the existing tension rolls will expand due to internal heat after long-term use, causing damage, and that the low hardness reduces the service life of the tension rolls.

Claims

1. A tension measuring roller anti-deformation mechanism, comprising a tension measuring roller body (2), characterized in that: A heat-conducting layer (10) is provided on the outer surface of the tension roller body (2). A reinforcing layer (5) is sleeved on the outside of the heat-conducting layer (10). A reinforcing module is provided inside the reinforcing layer (5) to strengthen the strength of the tension roller body (2). An outer rubber roller layer (1) is sleeved on the outside of the reinforcing layer (5). A guide groove (6) is provided on the inner wall of the outer rubber roller layer (1). Bearing seats (3) are provided on both the left and right sides of the tension roller body (2). A rotating shaft (4) is provided on one side of each of the two bearing seats (3). A heat insulation component is connected between the two bearing seats (3) and the tension roller body (2). The heat insulation component is used to block heat.

2. The anti-deformation mechanism for the tension measuring roller according to claim 1, characterized in that: The surface of the heat-conducting layer (10) is plated with hard chrome. By plating with hard chrome, the thermal conductivity is enhanced and the risk of local overheating is reduced.

3. The anti-deformation mechanism for the tension measuring roller according to claim 1, characterized in that: The guide grooves (6) are arranged in a ring array and there are multiple guide grooves (6) located in a spiral pattern on the inner wall of the outer rubber roller layer (1) for passing in constant temperature water to reduce thermal expansion.

4. The anti-deformation mechanism for the tension measuring roller according to claim 1, characterized in that: The heat insulation component includes a heat insulation pad (7), which is made of ceramic fiber material and is used to block the heat conduction during rolling to the bearing.

5. The anti-deformation mechanism for the tension measuring roller according to claim 1, characterized in that: The reinforcement module includes horizontal support beams (8), and there are multiple horizontal support beams (8) arranged vertically. Vertical support beams (9) are fixedly connected between the multiple horizontal support beams (8), and there are multiple vertical support beams (9) arranged in a horizontal array.

6. The anti-deformation mechanism for the tension measuring roller according to claim 5, characterized in that: Multiple transverse support beams (8) and multiple vertical support beams (9) are arranged in a cross shape on the surface of the tension roll body (2). Both the transverse support beams (8) and the vertical support beams (9) are made of alloy steel.

7. The anti-deformation mechanism for the tension measuring roller according to claim 1, characterized in that: One end of the bearing housing (3) is connected to a self-aligning ball bearing, which is used to reduce the skewness of the tension roll body (2) during installation.

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