Floating Multi-Piece Rolling Tool for Self-Alignment and Lower Wear
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Solution Overview
Problem
Existing rolling tools are costly to recondition and produce workpieces with suboptimal outer contours due to misalignment and wear issues, leading to increased maintenance and freight costs.
Innovation Solution
A rolling tool design featuring a basic body and profiled part that are separable and movable relative to each other in a plane perpendicular to the rolling direction, utilizing a floating mounting system to self-align and reduce wear, allowing for non-destructive separation and replacement of the profiled part, thereby reducing maintenance and freight costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the rolling tool is designed as a fixed multi-piece structure with screw connections, then the structural stability is improved, but the alignment precision deteriorates due to wear and misalignment over time
Solution Approach 1:
The patent applies the dynamics principle by making the profiled part movable relative to the basic body through a floating mounting system. This allows the previously static structure to become dynamic, enabling automatic alignment adjustment during operation. The profiled part can shift position to compensate for wear and maintain precise alignment with the workpiece, resolving the contradiction between structural stability and alignment precision.
Solution Approach 2:
The patent divides the rolling tool into separable segments - the basic body and the profiled part - connected through a floating mounting system. This segmentation allows independent movement and adjustment of the profiled part relative to the basic body, enabling the structure to maintain stability while achieving precise alignment through relative motion between segments.
2Strength
If the profiled part is made with considerable thickness for durability, then the strength is improved, but the material usage and costs increase
Solution Approach 1:
By making the profiled part movable through floating mounting, the patent enables a thinner design to achieve equivalent durability through dynamic adjustment and self-alignment capabilities. The reduced thickness is compensated by the ability of the profiled part to automatically adjust its position during operation, maintaining contact quality and distributing wear more effectively.
Solution Approach 2:
The patent changes the key parameter of the profiled part from static fixed thickness to dynamic adjustable position. Instead of relying solely on increased thickness for durability, the system uses parameter changes in position and orientation through floating mounting to achieve the same durability effect with less material.
3Ease of operation
If the rolling tool uses fixed mounting in grooves with play, then the ease of operation is improved, but the manufacturing precision deteriorates due to misalignment
Solution Approach 1:
The patent replaces the static fixed mounting in grooves with a dynamic floating mounting system. This allows the profiled part to move freely in the mounting plane and automatically align itself during operation, eliminating the misalignment problems caused by play in fixed groove mounting while maintaining ease of operation.
Solution Approach 2:
The floating mounting system enables the profiled part to self-align automatically during operation without requiring precise manual positioning or fixed constraints. The system serves itself by using operational forces to achieve proper alignment, eliminating the need for precision-machined grooves and play compensation.
4Reliability
If spring forces are used to hold the rolling tool in position, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The patent extracts and eliminates the spring forcing mechanism from the mounting system. Instead of using active spring forces to hold the rolling tool in position, the design relies on the passive floating mounting capability and operational forces to maintain proper positioning, thereby reducing device complexity while maintaining reliability.
Solution Approach 2:
The floating mounting system enables the rolling tool to self-position and self-align during operation without requiring external spring forces or active positioning mechanisms. The system uses the operational forces and geometry to automatically maintain reliable positioning, eliminating the need for complex spring-based positioning devices.
Data Source
AI summary
A rolling tool (5) has a basic body (6) for fastening the rolling tool (5) in a rolling machine (1) and a profiled part (7) for the shaping treatment of a workpiece (2) to be rolled. The basic body (6) and the profiled part (7) are of multi-piece design. The basic body (6) and the profiled part (7), in their interconnected position, are mounted movably relative to one another in a plane perpendicular to the rolling direction (23). The basic body (6) of the rolling tool (5) can also be part of the rolling machine (1).