Horizontal Roll Stand Layout for Faster Roll Changes
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Solution Overview
Problem
Existing roll forming machines for manufacturing welded pipes face challenges in quickly and efficiently changing horizontal rolls, often requiring complex configurations that increase costs and restrict the use of larger rolls due to size and rigidity constraints.
Innovation Solution
A roll forming machine design featuring a movable horizontal roll stand with open-top housings and a fixed stand with a cantilevered overhang part, equipped with a screw down device and housing supports, allows for easy and rapid roll changes by applying pressing forces and simplifying the configuration, reducing size and weight, and enabling closer stand placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the horizontal roll stand is ejected entirely during roll changing, then roll changing speed is improved, but the stand configuration becomes complex and manufacturing cost increases
Solution Approach 1:
The stand is divided into two independent parts: a fixed stand that remains in the forming line and a movable horizontal roll stand that can be ejected and replaced. This segmentation allows the movable stand to be changed quickly without requiring the entire stand structure to be complex, as the fixed stand provides stable support while the movable stand handles the roll changing operation.
2Ease of operation
If the horizontal rolls are coupled into a unit and ejected together, then roll changing is simplified, but the stand size increases and pitch between stands cannot be reduced
Solution Approach 1:
The horizontal roll stand is separated from the main stand structure, allowing it to be a compact, movable unit. This segmentation enables the roll changing operation to be simple and quick while keeping the stand size compact, as only the necessary roll housing and support components are included in the movable unit rather than the entire stand structure.
3Productivity
If the stand frame is divided into driving side and operation side, then roll changing is enabled, but the stand frame requires higher rigidity resulting in size and cost increase
Solution Approach 1:
The stand frame is segmented into a fixed stand that provides the necessary rigidity and support, and a movable horizontal roll stand that can be easily replaced. This segmentation allows the fixed stand to be optimized for strength and rigidity without increasing the weight of the movable components that need to be frequently changed.
Solution Approach 2:
The movable horizontal roll stand is extracted as a separate, replaceable unit from the main stand structure. This extraction allows the main stand frame to be designed for optimal rigidity and weight distribution, while the extracted movable unit can be lightweight and easy to handle for quick changing operations.
4Productivity
If the horizontal roll housing is supported in cantilever style, then roll changing is enabled, but the stand frame size and cost increase
Solution Approach 1:
The horizontal roll housing is segmented as a movable unit that can be ejected from the forming line, eliminating the need for a large cantilever-style support structure. The fixed stand provides compact support for the movable housing, reducing the overall stand frame volume while maintaining roll changing capability.
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 design enables prompt and simplified roll changing, reduces the size and weight of the roll forming machine, and lowers costs by allowing for more efficient configuration and operation, while maintaining the ability to use a variety of roll sizes without increasing the machine's size or complexity.
Implementation Method 1
a screw down 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
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.