Rolling cassette for rolling a ribbed metal wire and corresponding method

Abstract

Rolling cassette (10) for rolling a ribbed metal wire (100), comprising: at least two opposing rollers (12, 13, 14) defining between them a passage channel (15) for said metal wire (100) along a central axis (X), at least one measuring device (19) disposed downstream of said passage channel (15) and configured to detect at least one physical quantity (D) of said metal wire (100), and at least one actuator (18) configured to vary a current distance (gl, g2, g3) of said rollers (12, 13, 14) with respect to said central axis (X).

Description

[0001] “ROLLING CASSETTE FOR ROLLING A RIBBED METAL WIRE AND CORRESPONDING METHOD”

[0002] * * * * *

[0003] FIELD OF THE INVENTION

[0004] The present invention concerns a rolling cassette and a corresponding method for rolling a metal wire, preferably ribbed, suitable to usually be used in the construction sector, for example to create reinforcements for reinforced concrete.

[0005] BACKGROUND OF THE INVENTION

[0006] The need to use ribbed steel wires, rods or bars is well known in the construction industry, but not limited thereto. Their production requires careful analysis in terms of both mechanical and also dimensional properties, typically established by specific industry standards.

[0007] One of the most important parameters is the equivalent diameter which, due to the presence of the ribs on the wire’s surface, is difficult to identify and has to remain within a pre-established percentage tolerance range.

[0008] Of course, in the mass production of large quantities of ribbed wire, producing a wire with an equivalent diameter as close as possible to the lower limit imposed by the standard allows the manufacturer to save material, or produce more meters of wire, and therefore increase profits.

[0009] The ribbed wire is obtained in rolling plants provided with a plurality of rolling cassettes having opposing rollers defining a passage channel for the wire. These rollers are subject to wear, therefore the distance or gap between them has to be appropriately adjusted to obtain a product at exit that is always compliant.

[0010] Currently, the adjustment, at least with regards to ribbed wire, is a manual one, whereby an operator acts by changing the distance between the rollers only when they notice that the ribbed wire produced no longer complies with the tolerance required by the standard. The verification is done by cutting and weighing a piece of ribbed wire to obtain, through known correlations, the equivalent diameter. This, however, requires the process to be interrupted.

[0011] There is therefore the need to perfect a rolling cassette for rolling a ribbed wire that can overcome at least one of the disadvantages of the state of the art.

[0012] One purpose of the present invention is to automate the “on-the-fly” adjustment of the gap between the rolling cassette’s rollers without interrupting the process, based on a measured parameter of the ribbed wire at exit from the cassette.

[0013] The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.

[0014] SUMMARY OF THE INVENTION

[0015] The present invention is set forth and characterized in the independent claims. The dependent claims describe other characteristics of the present invention or variants to the main inventive idea.

[0016] In accordance with the above purpose and to resolve the technical problem described above in a new and original way, also achieving considerable advantages compared to the state of the prior art, a rolling cassette for rolling a ribbed metal wire according to the present invention comprises:

[0017] - at least two opposing rollers defining between them a passage channel for the metal wire along a central axis;

[0018] - at least one measuring device disposed downstream of the passage channel and configured to detect at least one physical quantity of the metal wire;

[0019] - at least one actuator configured to vary a current distance of the rollers with respect to the central axis;

[0020] - a processing and control unit operationally connected to the measuring device to receive a first signal containing the physical quantity, and to the at least one actuator to send a command signal to move the rollers.

[0021] In accordance with one aspect of the present invention, the processing and control unit is configured to run a computer program which, on the basis of the first signal, of a speed of advance of the metal wire, of a density of the material constituting the metal wire, allows to calculate a current mass flow and to optionally generate a command signal for the at least one actuator so as to keep the current mass flow within certain limits.

[0022] In accordance with another aspect of the present invention, the processing and control unit comprises a storage module in which the density is stored.

[0023] In accordance with another aspect of the present invention, the rolling cassette comprises at least one speed detection device configured to detect the speed of advance and transmit a corresponding signal to the processing and control unit.

[0024] In accordance with another aspect of the present invention, the rollers have a knurled external surface conformed to give the metal wire a certain rib.

[0025] The present invention also concerns a method for rolling a ribbed metal wire which comprises:

[0026] - feeding a metal wire along a passage channel defined between rollers of a rolling cassette along a central axis;

[0027] - measuring, by means of a measuring device, a physical quantity of the metal wire at exit from the passage channel and sending a first signal containing the physical quantity to the processing and control unit;

[0028] - running a computer program on the basis of a compensation algorithm which allows, at least on the basis of values correlated with the first signal, with a speed of advance of the metal wire, with a density of the material constituting the metal wire, to calculate a current mass flow and to optionally generate a command signal for at least one actuator, configured to vary a current distance of the rollers with respect to the central axis so as to keep the current mass flow within certain limits;

[0029] - moving the rollers to vary the current distance by means of the at least one actuator on the basis of the command signal.

[0030] In accordance with another aspect of the present invention, the processing and control unit also receives from sensors a third signal containing information on the current distance.

[0031] In accordance with another aspect of the present invention, the metal wire advances linearly parallel to the central axis at a speed comprised between 0.1 m / s and 20 m / s.

[0032] The present invention also concerns a computer-readable data carrier on which the computer program executed in the above described method is stored.

[0033] DESCRIPTION OF THE DRAWINGS

[0034] These and other aspects, characteristics and advantages of the present invention will become apparent from the following description of an embodiment, given as a non-restrictive example with reference to the attached drawings wherein:

[0035] - fig. 1 is a schematic lateral view of a part of a rolling cassette for rolling a ribbed metal wire, according to the present invention;

[0036] - fig. 2 is a front view of the rolling cassette of fig. 1 ;

[0037] - fig. 2a is an enlarged detail of fig. 2. We must clarify that the phraseology and terminology used in the present description, as well as the figures in the attached drawings also in relation as to how described, have the sole function of better illustrating and explaining the present invention, their purpose being to provide a non-limiting example of the invention itself, since the scope of protection is defined by the claims.

[0038] To facilitate comprehension, the same reference numbers have been used, where possible, to identify identical common elements in the drawings. It is understood that elements and characteristics of one embodiment can be conveniently combined or incorporated into other embodiments without further clarifications.

[0039] DESCRIPTION OF AN EMBODIMENT OF THE PRESENT INVENTION

[0040] With reference to fig. 1, this shows a rolling cassette 10 for rolling a metal wire 100, preferably already partly ribbed or to make it ribbed.

[0041] The term ribbed metal wire 100 is understood as a type of wire, typically made of steel, which has a lateral surface with longitudinal ribs, usually with a spiral, herringbone or stepped shape.

[0042] The metal wire 100 is produced in different sizes, with diameters ranging from about 3.4 mm to about 16 mm.

[0043] We must clarify that the rolling cassette 10 finds advantageous application for ribbed wire, but it can also be used for smooth wire.

[0044] The rolling cassette 10 comprises a box-shaped body 11 housing all the components. It is usually made of cast iron or worked steel to guarantee strength and wear resistance.

[0045] Inside the body 11 there are two or more rollers, in the example of figs. 1 and 2 there are three rollers 12, 13, 14, of which an upper one and two lower ones, which rotate in opposite directions. The rollers 12, 13, 14 can have an external surface with a knurling capable, during use, of giving the wire the desired ribbing, fig. 2.

[0046] The rollers 12, 13, 14 are disposed opposing each other so as to define between them a passage channel 15 for a metal wire 100. In the example of fig. 2, the rollers 12, 13, 14 are disposed at 120°. In the case of four rollers, they would be disposed at 90°. The passage channel 15 is defined along a central axis X in which the metal wire 100 is made to advance by the rotation of the rollers 12, 13, 14.

[0047] The rolling cassette 10 comprises adjustment means 16 that allow to vary the current distance gl, g2, g3 between the rollers 12, 13, 14, and therefore the pressure exerted on the metal wire 100. The current distance gl, g2, g3 between the rollers 12, 13, 14 essentially defines the cross-section area of the passage channel 15.

[0048] The adjustment means 16 comprise sensors 17 capable of measuring the position of the rollers 12, 13, 14 and the current distance gl, g2, g3 between them, and comprise at least one actuator 18, for example one actuator 18 for each roller 12, 13, 14, configured to move the rollers 12, 13, 14 on the basis of command signals received to vary the current distance gl, g2, g3. The actuators 18 can comprise motors, guides, supports, and are shown only by way of example in fig. 2.

[0049] The rolling cassette 10 comprises at least one motor 21 (fig. 1) configured to provide the driving force necessary to move the rollers 12, 13, 14. The rolling cassette 10 comprises at least one measuring device 19 disposed downstream of an exit section of the passage channel 15 and configured to detect at least one physical quantity D of the metal wire 100.

[0050] This physical quantity D can preferably be the current nominal or equivalent diameter of the wire 100.

[0051] The equivalent diameter is a value that represents the cross-section area of the wire, taking into account the rib. In other words, it is the diameter of a smooth wire that would have the same area as the ribbed wire.

[0052] The rolling cassette 10 comprises a processing and control unit 20 operationally connected to the measuring device 19 to receive a first signal SI containing the physical quantity D, and to the one or more actuators 18 to send a command signal S2 to move the rollers 12, 13, 14.

[0053] The movement of the rollers 12, 13, 14 is functional to vary the current distance gl, g2, g3. The current distance gl, g2, g3 can be conveniently considered with respect to the central axis X.

[0054] Optionally, the processing and control unit 20 can also receive a third signal S3 containing information on the current distance gl, g2, g3 received from the sensors 17. The third signal S3 can comprise a single signal for each of the sensors 17, or a combined signal containing all the necessary information.

[0055] The third signal S3 can be a continuous signal, or a signal “requested” by the processing and control unit 20 when necessary.

[0056] The processing and control unit 20 comprises a storage module 20a and a processing module 20b.

[0057] The unit 20 is programmed to execute a program on the basis of a compensation algorithm stored in the storage module 20a which allows, at least on the basis of values correlated with the first signal SI, optionally also with the third signal S3, with the speed of advance v of the metal wire 100, with the density p of the material constituting the metal wire 100, to calculate a current mass flow M, expressible for example in kg / s, and to keep the current mass flow M within certain pre-established limits Mmax and Mmin, for example stored in a specific database in the storage module 20a, possibly generating the command signal S2 for the one or more actuators 18 to move the rollers 12, 13, 14.

[0058] The speed of advance v of the ribbed wire is understood as linear and can be inferred from the speed of rotation of the rollers 12, 13, 14, for example by installing dedicated sensors.

[0059] In another example (fig. 1), the rolling cassette 10 can comprise a speed detection device 22 configured to detect the speed of advance v and transmit a corresponding signal V to the processing and control unit 20. The speed detection device 22 can be of the optical or laser type.

[0060] If the current mass flow M increases over time, it means that the rollers 12, 13, 14 do not exert an effective pressure on the ribbed metal wire 100 being worked. This may be due to an excessive current distance gl, g2, g3, or to wear of the work surface of one or more of the rollers 12, 13, 14. In addition to the risk of producing a ribbed metal wire 100 that does not comply with regulations (e.g. with an equivalent diameter out of tolerance), it becomes a waste of material for the manufacturer.

[0061] The computer program implemented by the processing and control unit 20 advantageously allows to automatically adjust the productivity of the rolling cassette 10. This advantage is even more felt in the case of a ribbed wire, since the ribs themselves prevent its fundamental quantities (e.g. equivalent diameter) from being measured accurately.

[0062] The rolling cassette 10 can comprise a user interface 23 connected, physically or wirelessly, to the processing and control unit 20 to display the results, fig. 1. The user interface 23 can be installed on the machine or can be remotely operated.

[0063] The user interface 23 can be physical, inclusive of screens, possibly touchscreens, keys, knobs, remote controls, or virtual, for example a smartphone and tablet application or a web interface.

[0064] The operation of the rolling cassette 10 described heretofore, which corresponds to the method for rolling a metal wire 100 according to the present invention, comprises the following steps.

[0065] Feeding SI 00 a metal wire 100 along a passage channel 15 defined between the rollers 12, 13, 14 of the rolling cassette 10 along the central axis X. The rollers 12, 13, 14 can have an external surface with a knurling capable of giving the wire the desired ribbing.

[0066] The metal wire 100 is fed with a preferably constant linear speed of advance v, comprised between about 0.1 m / s and about 20 m / s.

[0067] Measuring S200, by means of the measuring device 19, a physical quantity D of the ribbed wire 100 at exit from the passage channel 15 and sending a first signal SI containing the physical quantity D to the processing and control unit 20.

[0068] The physical quantity D is preferably the equivalent diameter of the ribbed wire 100.

[0069] Running S300 a computer program on the basis of a compensation algorithm that allows, at least on the basis of values correlated with the first signal SI, with the speed of advance v of the ribbed wire 100, with the density p of the material constituting the ribbed wire 100, to calculate a current mass flow M and to keep said current mass flow M within certain pre-established limits Mmaxand Mmm, possibly generating a command signal S2 for the one or more actuators 18.

[0070] Moving S400 the rollers 12, 13, 14 to vary the current distance gl, g2, g3 by means of the one or more actuators 18 on the basis of the aforementioned command signal S2.

[0071] It is clear that modifications and / or additions of parts may be made to the rolling cassette for rolling a ribbed metal wire and to the corresponding rolling method as described heretofore, without thereby departing from the field and scope of the present invention, as defined by the claims.

[0072] It is also clear that, although the present invention has been described with reference to some specific examples, a person of skill in the art will be able to achieve other equivalent forms of a rolling cassette for rolling a ribbed metal wire and corresponding rolling method, having the characteristics as set forth in the claims and hence all coming within the field of protection defined thereby.

[0073] In the following claims, the sole purpose of the references in brackets is to facilitate their reading and they must not be considered as restrictive factors with regard to the field of protection defined by the claims.

Claims

1. CLAIMS1. Rolling cassette (10) for rolling a ribbed metal wire (100), comprising:- at least two opposing rollers (12, 13, 14) defining a passage channel (15) for said metal wire (100) along a central axis (X),- at least one measuring device (19) disposed downstream of said passage channel (15) configured to detect at least one physical quantity (D) of said metal wire (100),- at least one actuator (18) configured to vary a current distance (gl, g2, g3) of said rollers (12, 13, 14) with respect to said central axis (X),- a processing and control unit (20) operationally connected to said measuring device (19) to receive a first signal (SI) containing said physical quantity (D) and connected to said at least one actuator (18) to send a command signal (S2) to move said rollers (12, 13, 14), wherein said processing and control unit (20) is configured to run a computer program which on the basis of said first signal (SI), of a speed of advance (v) of said metal wire (100), of a density p of the material constituting said metal wire (100), allows to calculate a current mass flow (M) and to optionally generate a command signal (S2) for said at least one actuator (18) so as to keep said current mass flow (M) within certain limits (Mmax, Mmin).

2. Rolling cassette (10) as in claim 1, characterized in that said processing and control unit (20) comprises a storage module (20a) in which said density p is stored.

3. Rolling cassette (10) as in claim 1 or 2, characterized in that it comprises at least one speed detection device (22) configured to detect said speed of advance (v) and transmit a corresponding signal (V) to said processing and control unit (20).

4. Rolling cassette (10) as in any claim hereinbefore, characterized in that said rollers (12, 13, 14) have a knurled external surface conformed to give said metal wire (100) a certain rib.

5. Method for rolling a ribbed metal wire (100) comprising:- feeding (S100) a metal wire (100) along a passage channel (15) defined between rollers (12, 13, 14) of a rolling cassette (10) along a central axis (X),- measuring (S200), by means of a measuring device (19), a physical quantity (D) of said metal wire (100) at exit from said passage channel (15) and sendinga first signal (SI) containing said physical quantity (D) to said processing and control unit (20),- running (S300) a computer program on the basis of a compensation algorithm which allows, at least on the basis of values correlated with said first signal (SI), with a speed of advance (v) of said metal wire (100), with a density p of the material constituting said metal wire (100), to calculate a current mass flow (M) and to optionally generate a command signal (S2) for at least one actuator (18), configured to vary a current distance (gl, g2, g3) of said rollers (12, 13, 14) with respect to said central axis (X), so as to keep said current mass flow (M) within certain limits (Mmax, Mmm),- moving (S400) said rollers (12, 13, 14) to vary said current distance (gl, g2, g3) by means of said at least one actuator (18) on the basis of said command signal (S2).

6. Method as in claim 5, characterized in that said processing and control unit (20) also receives from sensors (17) a third signal (S3) containing information on said current distance (gl, g2, g3).

7. Method as in claim 5 or 6, characterized in that said metal wire (100) advances linearly parallel to said central axis (X) at a speed comprised between 0.1 m / s and 20 m / s.

8. A computer-readable data carrier on which the computer program (S300) executed in the method as in one of the claims from 5 to 7 is stored.

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