Direct-Drive Ring Rolling Machine for Precise Axis Control
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Solution Overview
Problem
Ring rolling machines often have complex mechanical designs due to the need for hydraulic control systems and long, complex line paths, which can lead to precision issues and increased maintenance efforts.
Innovation Solution
The implementation of direct drives, specifically electro-hydrostatic actuators and high-torque torque motors, replaces hydraulic systems and gears, allowing for a simpler mechanical design while maintaining precision by directly controlling hydraulically controlled linear axes and roller shafts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hydraulic control systems with control lines and servo valves are used, then the mechanical design becomes complex, but the control precision is maintained
Solution Approach 1:
The patent replaces conventional hydraulic control systems (with control lines, servo valves, and hydraulic pumps) with direct electric drives (servo motors) that directly drive the roller shafts. This substitution eliminates the need for complex hydraulic infrastructure while maintaining precise control capability through direct electromagnetic actuation.
Solution Approach 2:
The patent extracts and removes the complex hydraulic control components (control lines, servo valves, hydraulic pumps) from the drive system, retaining only the essential drive function through direct electric motors connected to the roller shafts without intermediate mechanical or hydraulic transmission elements.
2Ease of operation
If long hydraulic control lines are routed to moving components, then the system can be controlled, but the reliability decreases and maintenance effort increases
Solution Approach 1:
The patent replaces hydraulic control lines with electrical connections through direct drives. The servo motors are directly mounted on or near the roller shafts, eliminating the need for long hydraulic lines that run to moving components. This direct electric connection significantly improves reliability by removing vulnerable hydraulic infrastructure.
3Force
If complex gearboxes are used in drive systems, then torque can be amplified, but the device complexity increases
Solution Approach 1:
The patent replaces mechanical gearboxes with direct electric drives (servo motors) that provide high torque output directly. The electric motors are selected with appropriate torque ratings to eliminate the need for mechanical gear multiplication, thereby simplifying the drive system while maintaining the required force output for ring rolling operations.
4Manufacturing precision
If hydraulic control systems are used for linear axes, then positioning can be achieved, but the mechanical design becomes complex and precision may be compromised
Solution Approach 1:
The patent replaces hydraulic control systems for linear axes with direct electric drives. Servo motors are used to directly drive the linear positioning mechanisms, providing precise control through electronic feedback systems while eliminating the need for hydraulic pumps, control lines, and valves that would complicate the mechanical design.
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 simplifies the mechanical design, reduces the need for complex hydraulic systems and gearboxes, and enhances precision and reliability, particularly in movable assemblies, by using direct drives for all hydraulically controlled axes and roller drives.
Implementation Method 1
The electro-hydrostatic actuator, also called an electro-hydrostatic direct drive, is generally characterized by the fact that electrical energy is converted into a corresponding mechanical linear movement via hydraulics within a housing.
Data Source
Figure 1
AI summary
A forming machine, in particular a ring rolling machine, comprising a hydraulically controlled linear axis driven by an electro-hydrostatic actuator, can operate precisely with a simple machine design. The invention further relates to a ring rolling machine with a direct drive.