Asynchronous Rolling Mill With Arc Plate for Large Diameter Ratios
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Solution Overview
Problem
Traditional rolling mills with different diameter rolls face issues of high friction, engagement difficulty, slippage, and inaccurate speed ratios, leading to poor strip quality and increased energy consumption due to limited diameter and speed ratio adjustments.
Innovation Solution
An asynchronous rolling mill with a super large diameter ratio, featuring a rolling mill stand, press-down device, balancing device, upper roll system, and arc-shaped plate device, which includes hydraulic cylinders, balancing beams, and a gear-and-rack transmission system, allowing for wide-range diameter and speed ratio adjustments, and a stabilizing mechanism to maintain arc-shaped plate stability during rolling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flat plate replaces the lower roll to achieve infinite diameter ratio, then the diameter ratio is improved, but friction increases and surface quality deteriorates
Solution Approach 1:
The patent replaces the flat plate with an arc-shaped plate that has a curved surface matching the workpiece contour. This curvature reduces the contact area and friction between the rolling device and workpiece, preventing surface damage while maintaining the large diameter ratio effect. The arc-shaped plate provides a more favorable contact geometry that reduces harmful frictional forces.
Solution Approach 2:
The patent introduces a gear-rack transmission mechanism as an intermediary between the drive system and the arc-shaped plate. This intermediary provides controlled engagement and disengagement, allowing the arc-shaped plate to be driven only when needed while minimizing continuous friction contact. The gear-rack system enables precise control of the rolling process without the harmful effects of continuous friction.
2Ease of operation
If traditional gearbox controls roll speeds, then speed control is achieved, but speed ratio adjustment range is limited
Solution Approach 1:
The patent replaces the traditional mechanical gearbox with an independent motor drive system for each roll. This substitution eliminates the fixed gear ratios of a gearbox and allows each roll to be driven at independently controlled speeds. The electronic control system enables continuous adjustment of speed ratios across a wide range, including large speed ratios that were impossible with traditional gearboxes.
Solution Approach 2:
The patent implements dynamic speed control where the rotation speeds of the upper roll and arc-shaped plate can be independently adjusted during operation. This dynamic control allows the speed ratio to be changed on-the-fly to match different workpiece requirements, providing adaptability that static gearbox systems cannot achieve.
3Loss of energy
If one work roll diameter is reduced to lower rolling pressure, then energy consumption decreases, but roll stiffness weakens
Solution Approach 1:
The patent employs asymmetric rolling where the upper roll and arc-shaped plate have different effective diameters. The arc-shaped plate has a very large radius (effectively flat) while the upper roll maintains a smaller, stiffer diameter. This asymmetric configuration allows the stiffer roll to provide structural strength while the large-diameter arc-shaped plate creates a long deformation zone that reduces rolling pressure and energy consumption.
Solution Approach 2:
The patent transitions from symmetric dual-roll rolling to an asymmetric system where one element (arc-shaped plate) effectively extends to infinity in diameter. This dimensional change creates a rolling configuration where the deformation zone length is determined by the curvature radius rather than roll diameter, allowing independent optimization of roll stiffness and rolling pressure.
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
This solution significantly reduces rolling force, energy consumption, and warpage, enhances plastic deformation, and ensures accurate speed ratios, while improving strip quality and production efficiency by dispersing rolling force through multi-point supports and adjusting the arc-shaped plate and roll diameters.
Implementation Method 1
the press-down device includes two pressing hydraulic cylinders
Implementation Method 2
the workpiece is plastically deformed to the required shape
Implementation Method 3
The workpiece moves to the rolling area with the frictional force coming from two work rolls
Data Source
AI summary
An asynchronous rolling mill with a super large diameter ratio comprises a rolling mill stand, a press-down device, a balancing device, an upper roll system, and an arc-shaped plate device. The arc-shaped plate device comprises an arc-shaped plate, the arc-shaped plate is arranged opposite to the upper roll, and the arc-shaped plate and the upper roll are cooperated to roll strips. The present disclosure also provides a method for rolling a strip using an asynchronous rolling mill with a super large diameter ratio. The asynchronous rolling mill can roll with super large diameter ratio and different speeds, and has a large angle to engage, thereby reducing the external friction force of a workpiece and improving strip forming quality.