Billet Rolling Mill Manipulator With Linear Motor Speed Control
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Solution Overview
Problem
Existing billet rolling mills face challenges in precisely controlling the linear speed of the blank during rolling due to variable tool diameters and uncontrolled elongation, leading to difficulties in adjusting movements and maintaining synchronization with shaping rolls.
Innovation Solution
A billet rolling mill equipped with a manipulator subassembly that includes a linear motor to control the blank's movement direction and apply tensile or braking forces, synchronized with the rolling tools, using primary and secondary magnetic elements to achieve precise speed control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a manipulator subassembly with a ram is used to push the blank between shaping rolls, then the blank can be fed into the rolling tools, but the linear speed of the blank cannot be precisely controlled due to variable tool diameters and uncontrolled elongation
Solution Approach 1:
The patent replaces the traditional mechanical ram-based manipulator system with a linear motor system. The linear motor directly drives the carriage along the direction of rolling, eliminating the need for complex mechanical transmission mechanisms. This substitution enables precise control of the blank's linear speed through electrical control, directly addressing the speed control precision issue while simplifying the overall system architecture.
Solution Approach 2:
The patent implements a dynamic control system where the linear motor's force output is continuously adjusted based on real-time feedback about the blank's position and speed. The control system dynamically compensates for variations in tool diameter and elongation effects, maintaining precise speed control throughout the rolling process. This dynamic adaptation resolves the contradiction between precision and complexity by using intelligent control rather than overly complex mechanical mechanisms.
2Ease of operation
If the ram is deactivated to follow the blank's movement during rolling, then the blank can be returned to the manipulator subassembly, but the movement becomes uncontrolled
Solution Approach 1:
The linear motor maintains continuous control over the carriage throughout the entire cycle, including during the blank return phase. Rather than deactivating the manipulator, the linear motor continues to exert controlled forces to guide the blank back to the starting position. This continuous control ensures precision is maintained throughout all phases of operation while preserving automatic operation.
Solution Approach 2:
The control system incorporates feedback mechanisms that monitor the blank's position and movement characteristics in real-time. During the return phase, this feedback information is used by the linear motor control system to adjust forces and maintain precise control. The feedback loop ensures that automatic operation does not sacrifice control precision, resolving the contradiction between ease of operation and manufacturing precision.
3Measurement precision
If the linear speed of the blank is determined by the relation v=r*ω, then the speed can be calculated from roll parameters, but the speed cannot be precisely determined due to variable tool diameters
Solution Approach 1:
The patent replaces the indirect speed determination method (using v=r*ω calculation based on roll parameters) with direct measurement and control using the linear motor system. The linear motor directly controls and measures the carriage speed, eliminating dependency on tool diameter measurements. This substitution provides precise speed determination regardless of tool diameter variations, resolving the contradiction between measurement precision and adaptability.
Solution Approach 2:
The control system dynamically adjusts the linear motor's operation based on real-time conditions, including tool diameter variations. Rather than relying on fixed geometric relationships, the system adapts its control parameters to maintain precise speed determination and control. This dynamic approach allows the system to accommodate tool diameter changes while maintaining high measurement precision.
4Reliability
If the manipulator subassembly movements are synchronized with shaping rolls rotation, then the rolling process can proceed smoothly, but the cycle time is extended due to uncontrolled blank elongation
Solution Approach 1:
The linear motor system provides dynamic control of the carriage speed, allowing real-time adjustment to compensate for blank elongation. The control system continuously monitors the rolling process and adjusts the carriage movement to maintain optimal synchronization with the shaping rolls, even as blank dimensions change. This dynamic control maintains process stability while minimizing cycle time extensions caused by uncontrolled elongation.
Solution Approach 2:
The control system uses feedback from sensors monitoring the rolling process to continuously adjust the linear motor's operation. This feedback mechanism detects variations in blank elongation and adjusts the carriage speed accordingly, maintaining synchronization with the shaping rolls. The closed-loop control ensures process reliability while optimizing cycle time by preventing excessive elongation delays.
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
The solution allows for precise adjustment of the blank's linear speed, improving the quality and efficiency of the rolling process by optimizing the rolling effect and reducing cycle time.
Implementation Method 1
The linear motor is configured for accelerating the blank, so as to insert the blank between the rolling tools with a speed synchronized with the speed of the rolling tools, and for selectively exerting on the blank, either a tensile force, which tends to extract the blank from a gap defined between the rolling tools, or a braking force, which tends to limit a speed of ejection of the blank
Data Source
AI summary
The billet rolling mill comprises two rolls for shaping a blank, each shaping roll being provided with at least one rolling tool and being rotated about an axis of rotation by a drive motor, and a manipulator subassembly for moving the blank with respect to the shaping rolls. The manipulator subassembly comprises a clamp gripping the blank and a carriage moving the clamp at least along a direction of rolling of the blank. The manipulator subassembly comprises a linear motor moving the carriage along the direction of rolling. The direction of rolling is perpendicular to the axis of rotation of the rolling tool. The linear motor is configured for accelerating the blank and selectively exerting on the blank, either a tensile force, to extract the blank from a gap defined between the rolling tools, or a braking force, to limit a speed of ejection of the blank.