Compact Roll Polisher With Nested Actuators
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Solution Overview
Problem
Roll polishers face challenges in effectively polishing rollers in manufacturing due to space constraints and the need for efficient surface defect removal in various industries, such as steel, copper, and paper production.
Innovation Solution
A compact roll polisher design utilizing a tube with pivot and transverse actuators that can engage and disengage a polishing pad on the roller surface, allowing for transverse movement and applying a force of up to 100 lbs to smooth the surface, while maintaining a small operational envelope suitable for rollers from 50 to 120 inches wide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a traditional roll polisher design is used, then the polishing force can be sufficient, but the device requires excessive space and cannot fit in restrictive environments
Solution Approach 1:
The transverse actuators are positioned inside the tube, nesting one component within another. This allows the polisher to maintain a compact 11x9 inch envelope while still providing sufficient polishing force through the integrated actuator system.
Solution Approach 2:
The pivot actuators enable dynamic engagement and disengagement of the rolling pad on the roller surface. This dynamic capability allows the system to apply up to 100 lbs of force when needed while maintaining a compact footprint when retracted.
2Area of stationary object
If the roll polisher is designed for small envelope, then it fits restrictive spaces, but the transverse movement capability is reduced
Solution Approach 1:
The transverse actuators are positioned inside the tube, nesting one component within another. This allows the polisher to maintain a compact 11x9 inch envelope while still providing sufficient polishing force through the integrated actuator system.
Solution Approach 2:
The tube serves multiple functions: it acts as the structural frame, houses the transverse actuators, and provides the mounting structure for support mounts. This merging of functions reduces the overall envelope while maintaining transverse movement capability.
3Productivity
If the polishing bar is constantly engaged with the roller, then continuous polishing occurs, but the device cannot be disengaged for positioning or non-use periods
Solution Approach 1:
The pivot actuators enable dynamic engagement and disengagement of the rolling pad on the roller surface. This dynamic capability allows the system to apply up to 100 lbs of force when needed while maintaining a compact footprint when retracted.
Solution Approach 2:
The system can autonomously engage and disengage the polishing bar through the pivot actuators controlled by the PLC, allowing automatic operation cycles without manual intervention for engagement/disengagement.
4Ease of repair
If the transverse actuators are positioned outside the tube, then access for maintenance is easier, but the operational envelope increases
Solution Approach 1:
The transverse actuators are positioned inside the tube, nesting one component within another. This allows the polisher to maintain a compact 11x9 inch envelope while still providing sufficient polishing force through the integrated actuator system.
Solution Approach 2:
The tube can be designed with access ports or removable sections that allow maintenance personnel to reach inside and service the transverse actuators without increasing the external envelope, utilizing the internal volume for both operation and maintenance access.
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 enables effective surface smoothing and defect removal on rollers within restrictive spaces, ensuring high-quality flat surfaces for various materials, with adjustable force and envelope sizes to accommodate different manufacturing needs.
Implementation Method 1
The pivot actuators may apply a force of approximately 100 lbs. to the rolling surface to remove defects and smooth the surface of the roller
Implementation Method 2
Transverse actuators are used to move the tube, and thus, the rolling pad, transversely back and forth across the surface of the roller
Implementation Method 3
the pivot actuators may apply a force of approximately 100 lbs. to the rolling surface to remove defects and smooth the surface of the roller
Data Source
AI summary
Embodiments of the present invention relate to roll polishers that may be utilized with rollers in rolling stands that have restrictive space requirements. The roll polisher of the present invention comprises a tube with pivot actuators used to engage and disengage a rolling pad on the surface of a roller. Transverse actuators may be located at least partially within the tube, or in other embodiments located outside of the tube, and used to move the tube, and thus, the rolling pad, transversely back and forth across the surface of the roller. The roll polisher may operate apply a force to the pad engaging the rolling surface to remove defects and smooth the surface of the polisher.