Dual-Roll Grasping Tool for Faster Rolling Mill Roll Changes
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Solution Overview
Problem
Current roll-change operations in rolling mills are time-consuming and hazardous due to the need for manual handling of heavy rolls, which disrupts productivity and poses risks to operators during the extraction and insertion of rolls in a 20-roll rolling mill.
Innovation Solution
A grasping tool designed to simultaneously grasp two rolling rolls, equipped with a frame, holding system, and robotic system that allows parallel movement to adjust and lock the rolls, enabling simultaneous extraction and insertion of rolls, reducing cycle time and enhancing safety by minimizing operator involvement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling of heavy rolls is used during roll-change operations, then operators can guide the extraction and insertion processes, but the operations become time-consuming and hazardous due to the need for continuous manual intervention and the heavy weight of the rolls
Solution Approach 1:
The patent replaces manual mechanical handling with an automated robotic system equipped with a specialized grasping tool. The robotic arm with the dual-housing grasping tool automatically extracts and inserts rolls without continuous manual intervention, while operators can still monitor and guide the process through control systems, thus improving productivity while maintaining operational control.
Solution Approach 2:
The patent introduces a counterweight mechanism as an intermediary between the robotic system and the heavy rolls. The counterweight balances the roll during extraction and insertion, reducing the effective load on the robotic system and enabling safer, faster automated handling without requiring operators to physically support the heavy rolls.
2Ease of operation
If manual handling of heavy rolls is used during roll-change operations, then operators can guide the extraction and insertion processes, but the operations pose risks to operators due to possible swinging movements of heavy elements
Solution Approach 1:
The patent replaces manual handling with an automated robotic system that performs all extraction and insertion operations. The robotic arm with the grasping tool completely eliminates operator exposure to swinging heavy rolls, while operators retain guidance capability through remote control and monitoring systems, thus resolving the safety risk while maintaining operational control.
Solution Approach 2:
The patent employs a counterweight mechanism that balances the heavy rolls during automated extraction and insertion. This counterweight system stabilizes the rolls, preventing dangerous swinging movements that would otherwise pose risks to operators, while the robotic system executes the balanced motion safely and predictably.
3Ease of operation
If rolls are handled one by one during roll-change operations, then the extraction and insertion processes can be controlled, but the cycle time increases significantly
Solution Approach 1:
The patent merges the extraction of multiple rolls into a single automated operation. The grasping tool with multiple housings can simultaneously grasp and extract multiple rolls in one motion, and similarly insert multiple rolls in one operation. This combining of previously sequential operations into parallel simultaneous operations dramatically reduces cycle time while the robotic control system maintains precise process control.
Solution Approach 2:
The patent employs a dynamically adjustable grasping tool with movable housings that can adapt their positions and movements. The housings can move independently or in coordination to accommodate different roll configurations and enable simultaneous extraction/insertion of multiple rolls, optimizing the process speed while maintaining control through the robotic system's dynamic coordination capabilities.
4Productivity
If a robotic system is introduced to automate roll handling, then productivity and safety are improved, but the device complexity increases
Solution Approach 1:
The patent designs a universal robotic system with a multi-functional grasping tool that can handle various types of rolls (work rolls, intermediate rolls, backup rollers) with a single device configuration. The grasping tool's adjustable housings and the robotic arm's multiple degrees of freedom enable the system to perform extraction, insertion, and positioning of different roll types without requiring multiple specialized devices, thus managing complexity while achieving high productivity.
Solution Approach 2:
The patent segments the complex roll-handling task into distinct functional modules: the robotic arm for positioning and movement, the grasping tool with multiple housings for secure attachment, the counterweight mechanism for balancing, and the control system for coordination. This modular segmentation allows each component to be optimized independently while working together as an integrated system, managing overall complexity through functional decomposition.
Data Source
AI summary
A grasping tool including a chassis equipped with a fastening part configured to be manipulated by a robotic system, a holding system including a first recessing system with a first housing configured to receive and house recessed an end of a first rolling roll and a second recessing system having a second housing for receiving and housing recessed an end of a second rolling roll, a mechanism adjusting the centre distance including a slide system between the first recessing system and the second recessing system, allowing an adjustment of the separation between the first recessing system and the second recessing system.