Billet Rolling Manipulator With Linear Motor Speed Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing blank rolling mills face challenges in precisely controlling the linear speed of blanks during the rolling process due to variable tool diameters and uncontrolled elongation, leading to inaccuracies in geometry and elongation control.
Innovation Solution
A blank rolling mill equipped with a manipulator sub-assembly featuring a linear motor that accelerates and moves the blank between shaping cylinders, allowing for precise control of linear speed through electromagnetic forces, enabling synchronized movement with rolling tools and precise traction or braking efforts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a jack is used to push the blank between shaping rolls with variable diameter tools, then the blank can be moved between rolls, but the linear speed of the blank cannot be determined precisely and elongation is not fully controlled
Solution Approach 1:
The patent replaces the traditional mechanical jack system with a linear motor system. The linear motor directly drives the carriage along the rolling direction, eliminating the need for complex mechanical transmission mechanisms. This substitution enables precise control of the blank's linear speed through electromagnetic force, while simplifying the overall manipulator structure by removing intermediate mechanical components like cranks and connecting rods.
Solution Approach 2:
The patent changes the control parameter from indirect mechanical positioning to direct electromagnetic force control. By using a linear motor, the system can precisely adjust the linear speed parameter of the blank during rolling, ensuring it matches the synchronous speed requirement (v = r * ω) despite variations in tool diameter. This parameter control is achieved through electrical signal regulation rather than mechanical adjustment.
2Manufacturing precision
If the manipulator subassembly movements are synchronized with shaping rolls rotation, then the blank geometry is controlled, but the linear speed precision is compromised due to variable tool diameters
Solution Approach 1:
The linear motor replaces the traditional mechanical synchronization mechanism. Instead of relying on the relationship v = r * ω with variable r (tool radius), the linear motor directly controls the carriage speed through electromagnetic force. This allows the system to maintain synchronous movement with the rolls while precisely controlling the blank's linear speed, decoupling the speed control from the variable tool diameter.
Solution Approach 2:
The system implements speed synchronization control where the linear motor adjusts the carriage movement based on the rotational position of the shaping rolls. This feedback mechanism ensures that the blank is always positioned correctly relative to the tools while maintaining precise linear speed control, even as tool diameters vary during the rolling process.
3Manufacturing precision
If a linear motor is used to drive the carriage, then precise linear speed control is achieved, but the device complexity increases
Solution Approach 1:
While the linear motor itself is a sophisticated device, it replaces an equally complex mechanical transmission system that would be required to achieve the same precision with traditional motors. The linear motor provides direct linear motion without intermediate mechanical components, reducing overall system complexity despite the advanced nature of the motor itself.
Solution Approach 2:
The linear motor performs multiple functions: it drives the carriage along the rolling direction, controls the blank's linear speed precisely, and enables synchronized movement with the shaping rolls. This multi-functionality consolidates what would otherwise require multiple separate mechanical systems into a single device, reducing overall complexity.
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 enables precise adjustment and control of blank movement, enhancing the rolling process's accuracy and compatibility with high-speed production by defining the linear speed of the blank in the rolling direction, thus improving the overall rolling mill's efficiency and geometry control.
Implementation Method 1
The manipulator subassembly comprises at least one linear motor for moving the carriage in the rolling direction... allows for precise control of linear speed through electromagnetic forces
Data Source
Figure 1
Figure 2
Figure 3
AI summary
This billet rolling mill comprises two forming cylinders for a blank (E) to be shaped, each forming cylinder being equipped with at least one rolling tool and driven in rotation about an axis of rotation by at least one respective drive motor, and a manipulator subassembly (20) for moving the blank relative to the forming cylinders. This manipulator subassembly includes a gripper (39) for holding the blank and a carriage (35) for moving the gripper at least in one rolling direction (X38) of the blank. The manipulator subassembly (20) includes at least one linear motor (200) for moving the carriage (35) in the rolling direction (X38).