Removable Roll Support Plate for ERW Pipe Squeeze Roll Changes
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Solution Overview
Problem
Conventional squeeze devices for electric resistance welded pipe manufacturing lines face challenges in roll changing, including complex configurations, increased size and weight, and inefficient operations, particularly for middle-diameter and large-diameter pipes, which hinder economic efficiency and workability.
Innovation Solution
A squeeze device with a U-shaped fixed stand and a slidable roll support plate that omits the lower roll, allowing for simplified roll changing by lifting the roll support plate and screws down the side and upper rolls independently, reducing the number of rolls and eliminating the need for detaching the mandrel bar, thus simplifying the configuration and reducing weight and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If five-direction rolls are used for middle-diameter and large-diameter pipes, then the pipe squeezing function is improved, but the device complexity and roll changing difficulty increase
Solution Approach 1:
The patent divides the squeeze device into two independent parts: a fixed stand and a movable roll support plate. The roll support plate can be independently removed from the fixed stand, allowing rolls to be changed without moving the entire complex five-direction roll assembly. This segmentation resolves the contradiction by maintaining the five-direction roll configuration when needed while enabling simple roll changing through plate removal.
Solution Approach 2:
The roll support plate is designed to be movable relative to the fixed stand, transitioning between an inserted state (during operation) and a removed state (during roll changing). This dynamic design allows the system to adapt between operational complexity and maintenance simplicity, resolving the contradiction between maintaining five-direction roll functionality and enabling easy roll changing.
2Reliability
If five-direction rolls are used for middle-diameter and large-diameter pipes, then the pipe squeezing function is improved, but the operation speed of roll changing decreases
Solution Approach 1:
By segmenting the squeeze device into a fixed stand and a removable roll support plate, the patent enables rapid roll changing. The roll support plate with mounted rolls can be quickly removed from the fixed stand using a crane, significantly reducing roll changing time compared to conventional methods where individual rolls or complex assemblies must be manually handled.
Solution Approach 2:
The roll support plate acts as an intermediary carrier that holds multiple rolls together as a single unit. This intermediary structure allows the crane to lift and replace entire roll assemblies simultaneously, dramatically increasing roll changing speed while maintaining the five-direction roll configuration for proper pipe squeezing function.
3Ease of operation
If a roll support plate with all rolls is lifted by a crane, then roll changing is simplified, but the weight to be lifted increases
Solution Approach 1:
The patent segments the heavy components (rolls and support structure) from the fixed stand, concentrating them on the removable roll support plate. This segmentation allows the crane to lift only the necessary components (plate and rolls) rather than the entire squeeze device, making the operation feasible while maintaining simplicity.
Solution Approach 2:
The roll support plate with rolls is extracted as a separate removable unit from the fixed stand. This extraction allows the heavy roll assembly to be handled independently by the crane without moving the entire squeeze device structure, reducing the effective lifting weight to only the plate and rolls rather than the complete assembly.
4Weight of stationary object
If the lower roll is omitted from the squeeze device, then the device size and weight are reduced, but the support function for the pipe may be compromised
Solution Approach 1:
The side rolls are designed with tiltability, allowing them to dynamically adjust their orientation. When tilted outwardly, they provide downward thrust that compensates for the missing lower roll support function. This dynamic adjustment maintains pipe support reliability while enabling the omission of the lower roll for reduced device weight.
Solution Approach 2:
The patent changes the operational parameters of the side rolls from vertical orientation to tilted orientation. This parameter change allows the side rolls to generate both horizontal squeezing force and downward support force, replacing the function previously provided by a dedicated lower roll, thereby reducing device weight while maintaining support function.
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 significantly improves workability and economic efficiency by simplifying roll changing operations, reducing the device's size and weight, and enhancing the quality of manufactured pipes by minimizing roll scars and optimizing the distance from the work coil to the welding point.
Implementation Method 1
opposing edge portions of the open pipe are heated by induction
Implementation Method 2
the heated opposing edge portions are pressed with a squeeze roll to be joined by welding
Data Source
AI summary
[Problem to be solved] To provide a squeeze device of excellent economic efficiency and excellent workability for electric resistance welded pipe manufacturing having a simple configuration, achieving size reduction and weight reduction easily, and allowing operation in roll changing to be performed simply.[Solution] The squeeze device includes: a U-shaped fixed stand 10 with an open top; and a slidable roll support plate 60 inserted into the U-shaped fixed stand 10 through the open top of the U-shaped fixed stand 10 and held in the U-shaped fixed stand 10 in a manner allowing taking off of the roll support plate 60. The roll support plate 60 supports right and left side rolls 40 in a pair and an upper roll 50 on an upstream-side main surface in a manner allowing the side rolls 40 and the upper roll 50 to move in screw down directions. The roll support plate 60 has space 61 for passage of the pipe-shaped material formed at a position surrounded by these rolls. The space 61 is a part of a cutout-shaped opening opened toward a lower edge of the roll support plate 60. Each of the right and left side rolls 40 in a pair is a tilted roll with a corresponding roll shaft 42 tilted outwardly toward a higher position.