Flatness Measuring Pulley Layout to Avoid Torque-Induced Error
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Solution Overview
Problem
Existing tension pulley systems in strip straightening and re-rolling processes face measurement errors due to torque-induced deformation of pulley bodies and coatings, which affect the accuracy of force sensors used for flatness measurement.
Innovation Solution
Designing a tension pulley set with a first tensioning pulley as a flatness measuring pulley without a drive or with a weaker auxiliary drive, and a second tensioning pulley with a stronger drive, to minimize torque-induced deformation and improve measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a drive is provided for the first tensioning pulley to apply torque, then the tensioning function is improved, but measurement accuracy deteriorates due to torque-induced deformation
Solution Approach 1:
The tensioning pulley system is segmented into two distinct pulleys: a first tensioning pulley dedicated to measurement functions without a drive, and a second tensioning pulley with a drive for tensioning. This segmentation separates the measurement function from the tensioning function, allowing each component to optimize its specific purpose without interfering with the other.
Solution Approach 2:
The first tensioning pulley acts as an intermediary element between the strip and the measurement system. By positioning this undriven pulley between the driven second pulley and the measurement sensors, it transmits the strip movement while maintaining a stable, deformation-free reference for accurate flatness measurement.
2Force
If a stronger drive is applied to the first tensioning pulley, then the tensioning effectiveness is improved, but pulley deformation increases affecting measurement
Solution Approach 1:
The system is divided into a first tensioning pulley that remains free of drive mechanisms and a second tensioning pulley that carries the drive. This segmentation ensures that the first pulley maintains its structural integrity and does not suffer from torque-induced deformation, while the second pulley handles all tensioning forces.
3Productivity
If torque is applied to the first tensioning pulley, then the tensioning function is enhanced, but measurement reliability deteriorates
Solution Approach 1:
The drive mechanism is extracted from the first tensioning pulley and relocated to the second tensioning pulley. This extraction removes the source of torque-induced deformation from the measurement-critical first pulley, ensuring reliable flatness measurements while the second pulley maintains process efficiency through effective tensioning.
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 configuration enhances the accuracy of flatness measurement, leading to better straightening and re-rolling of strips by reducing measurement errors and maintaining pulley integrity.
Implementation Method 1
the first tensioning pulley (8) is a flatness measuring pulley having a force sensor for measuring a radial force (FR,1) applied to the circumferential surface of the flatness measuring pulley
Implementation Method 2
a drive (not shown in more detail) for the second tensioning pulley (9) is provided, with which a torque can be applied to the second tensioning pulley (9) on the second pulley axis
Implementation Method 3
a belt (2) is guided over the first tensioning pulley (8) and over the second tensioning pulley (9)
Data Source
AI summary
A tensioning pulley set for a straightening machine for straightening a strip or for a re-rolling stand for re-rolling a strip, comprising a first tensioning pulley with a first pulley axis and at least one second tensioning pulley with a second pulley axis, the first tension pulley being a flatness measuring pulley having a force sensor for measuring a radial force applied to the circumferential surface of the flatness measuring pulley, and a drive for the second tensioning pulley with which a torque can be applied thereto on the second pulley axis, either the first tensioning pulley configured without a drive, or an auxiliary drive provided for the first tensioning pulley with which a torque can be applied to the first tensioning pulley on the first pulley axis, the auxiliary drive for the first tensioning pulley being significantly weaker than the drive for the second tensioning pulley.