Horizontal Roll Stand With Fixed Pressure Device for Quick Roll Change
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Solution Overview
Problem
Existing roll forming machines for manufacturing welded pipes face challenges in quickly and efficiently changing horizontal rolls, leading to increased complexity, cost, and size due to complicated configurations and rigidity requirements, which limit the diameter of rolls that can be used.
Innovation Solution
A roll forming machine with a movable horizontal roll stand and a fixed stand featuring an overhang part with a pressure device and housing supports allows for easy readjustment and prompt changing of horizontal rolls by applying a pressing force through the opened tops of the roll housing, simplifying the configuration and reducing size and weight, while maintaining economic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the horizontal roll stand is disassembled and the forming roll is recombined outside the forming line, then the roll changing can be done, but it takes time for removing the pressure device
Solution Approach 1:
The pressure device is separated from the horizontal roll stand and fixed to the stand frame. This segmentation allows the roll housing to be removed and replaced independently without the pressure device, eliminating the time-consuming process of removing and reattaching the pressure device during roll changes.
Solution Approach 2:
The pressure device is extracted from the movable roll stand and fixed to the stationary stand frame. This extraction allows the roll changing operation to be performed without the pressure device, which remains in place, thus reducing the time required for roll changes while maintaining the necessary pressing function.
2Ease of operation
If upper and lower horizontal rolls are coupled into a unit and ejected by a carriage, then the roll changing is simplified, but the configuration of the entire stand becomes complicated and cost increases
Solution Approach 1:
The roll housing is designed as a separate, self-contained unit that can be easily removed and replaced. The horizontal rolls remain coupled within this housing, maintaining operational simplicity while avoiding the need for a complicated carriage-based ejection system. The segmentation isolates the rolls from the main stand structure.
Solution Approach 2:
The horizontal rolls are extracted from the main stand structure and placed within a separate roll housing that can be independently removed. This extraction simplifies the overall stand configuration by eliminating the need for complex carriage mechanisms while maintaining ease of roll changing.
3Productivity
If the stand frame is dividable into driving side and operation side, then the roll changing can be performed, but the stand frame requires higher rigidity resulting in size increase and cost increase
Solution Approach 1:
The stand frame is segmented into a fixed portion and a movable roll housing portion. The fixed portion maintains the necessary rigidity and supports the pressure device, while the movable roll housing can be easily removed and replaced. This segmentation allows roll changing capability without requiring the entire stand frame to have high rigidity, reducing overall weight.
Solution Approach 2:
The roll housing is extracted from the main stand frame structure, allowing it to be removed and replaced independently. The stand frame itself can be designed with lower rigidity requirements since it only needs to support the fixed portion and pressure device, not the entire roll assembly, thereby reducing weight and cost.
4Ease of manufacture
If the stand configuration is simplified, then the cost is reduced, but the pitch between stands cannot be reduced
Solution Approach 1:
The roll forming system is segmented into compact, modular units with the pressure device fixed to the stand frame and rolls housed in removable housings. This segmentation creates a compact configuration that reduces the pitch between stands while maintaining simple, cost-effective manufacturing.
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 rapid and efficient roll changing with reduced complexity and cost, allowing for smaller pitch between stands and avoiding the need for complicated readjustment of pressing forces, thus enhancing the economic performance and flexibility of the roll forming machine.
Implementation Method 1
a pressure device that applies a pressing force to the horizontal rolls in the horizontal roll housing in the forming line via the opened tops
Data Source
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AI summary
Changing of a horizontal roll in a horizontal roll stand involving readjustment of an amount of pressing is to be done readily and promptly. In order to achieve this, a horizontal roll stand 10 with a pair of built-in upper and lower horizontal rolls 11 is configured to retreat toward one side across a forming line. A fixed stand 40 stands upright on a counter-retreating side of the forming line. An overhang part 42 of the fixed stand 40 jutting out over the forming line is provided with a pressure device 43 that applies a pressing force to the horizontal rolls 11. The horizontal roll stand 10 includes a horizontal roll housing 12 with an opened top, receives the pressing force from the pressure device 43 via the opened top, and retreats to the outside of the forming line while the pressure device 43 is left on the forming line. The overhang part 42 of the fixed stand 40 is engaged with the horizontal roll housing 12 of the horizontal roll stand 10 to support the horizontal roll housing 12 in the forming line.