Rolling Assembly Accumulator Monitoring for Fast Emergency Roll Opening
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Solution Overview
Problem
Existing rolling assemblies face limitations in adjusting the distance between rolls quickly, particularly during emergency stops, due to the slow velocity of hydraulic fluid displacement, which compromises operational safety.
Innovation Solution
Incorporating a hydraulic accumulator with a first and second accumulator chamber, filled with hydraulic fluid and compressible gas respectively, and a moveable separating member, along with a measuring device to continuously monitor the position of the separating member, allowing for rapid adjustment of roll distance and continuous energy storage and release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a pump with limited displacement volume is used to adjust hydraulic cylinders, then the system is cost-effective, but the velocity of roll distance adjustment is limited to slow velocities
Solution Approach 1:
The hydraulic accumulator pre-stores hydraulic fluid under pressure in advance. During emergency stops, this pre-stored fluid is rapidly discharged to the hydraulic cylinders, enabling fast roll separation without requiring a high-displacement pump during normal operation. This resolves the contradiction by preparing the system beforehand to deliver high speed when needed while maintaining cost-effectiveness through the use of a smaller pump.
2Speed
If a hydraulic accumulator is added to achieve higher adjusting velocities during emergency stops, then the roll separation speed improves, but the device complexity increases
Solution Approach 1:
The hydraulic accumulator serves multiple functions: it acts as an energy storage device for emergency stops, a pressure regulator for the hydraulic system, and a cushioning element for normal operation fluctuations. By integrating these multiple functions into a single component, the system achieves high roll separation velocity without proportionally increasing complexity, as the accumulator replaces or supplements existing hydraulic components rather than adding entirely new systems.
3Reliability
If the gap between rolls must reach 50 mm within 5 seconds for safety reasons, then operational safety is improved, but the hydraulic system requires higher power to achieve this rapid adjustment
Solution Approach 1:
The hydraulic accumulator operates in periodic cycles: during normal operation, the pump slowly refills the accumulator with hydraulic fluid under pressure; during emergency stops, the stored fluid is rapidly discharged. This periodic charging and discharging allows the system to meet the high power demand for rapid roll separation (50 mm in 5 seconds) without requiring the pump to continuously operate at high power, thus improving safety while managing power requirements through time-based operation patterns.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures rapid roll separation during emergencies, reduces cycle time, and continuously monitors accumulator functionality, enhancing operational safety and efficiency.
Implementation Method 1
A compressible gas is disposed within the second accumulator chamber
Implementation Method 2
The hydraulic accumulator is configured to have an effect on the roll pair to move the roll pair from the working position to the safety position
Data Source
AI summary
A rolling assembly, including at least one roll pair with two cooperating rolls and a safety device. The safety device includes a hydraulic accumulator and a measuring device. The hydraulic accumulator includes an accumulator with a first and second accumulator chamber. A hydraulic fluid is disposed within the first accumulator chamber. A compressible gas is disposed within the second accumulator chamber. The hydraulic accumulator includes a moveably arranged separating member separating the first accumulator chamber from the second accumulator chamber. The roll pair has a working position and a safety position. A radial distance between the rolls is larger in the safety position than in the working position. The hydraulic accumulator is configured to move the roll pair from the working position to the safety position. The measuring device is configured to continuously detect a position of the separating member within the hydraulic accumulator.