Hot-Rolling Machine Parallel Wire Rod Processing
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Solution Overview
Problem
Current hot-rolling machines for producing reinforced concrete rods face limitations in production rate due to wire rod jamming at high speeds, necessitating line bifurcation which increases machine count and operational costs.
Innovation Solution
A hot-rolling machine design that allows for parallel hot-rolling of two wire rods at high speeds by arranging roller-provided rolling units with counter-rotating mills and a single drive unit, optimizing the arrangement of rolling units and drive mechanisms to maintain efficiency without the need for line bifurcation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wire rod feeding speed is increased above 30-40 meters per second, then productivity is improved, but wire rod tends to jam in the hot-rolling line
Solution Approach 1:
The patent divides the single wire rod into two separate wire rods by longitudinal splitting, creating two independent rolling paths. This segmentation allows each rod to be processed separately at high speeds without jamming, while the overall production rate is doubled. The splitting occurs before the rolling line, and each subsequent rolling unit processes one rod at a time independently.
Solution Approach 2:
The patent introduces a new dimension to the rolling line configuration by creating parallel processing paths. Instead of a single sequential path that causes jamming at high speeds, the system uses two parallel paths (after splitting) that can operate independently at high speeds, effectively adding a spatial dimension to the production flow.
2Productivity
If line bifurcation is implemented to increase production rate, then productivity is improved, but device complexity and machine count increase
Solution Approach 1:
The patent makes the rolling units universal by designing them to handle both single-rod and dual-rod configurations. Each rolling unit is equipped with two rolling mills that can process two separate wire rods simultaneously when the line is in bifurcated mode, or can be reconfigured for single-rod processing. This multi-functionality allows the same hardware to serve multiple purposes without requiring entirely separate machine sets.
Solution Approach 2:
The patent introduces dynamic reconfigurability to the rolling line, where the arrangement of rolling units and the feeding paths can be adjusted between single-rod and dual-rod modes. The system dynamically adapts its configuration based on production requirements, allowing the same physical infrastructure to support different operational modes without permanent structural changes.
3Manufacturing precision
If rolling units are arranged alternatively in horizontal and vertical position, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent employs asymmetric arrangement of rolling units, where consecutive rolling units are positioned alternately in horizontal and vertical orientations. This asymmetric pattern creates the necessary variation in necking directrix orientation to achieve proper wire rod deformation and rounding, while maintaining a regular, predictable sequence that simplifies the overall design and operation compared to random or complex arrangements.
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
Enables high-speed wire rod rolling up to 100-120 meters per second with reduced machine complexity and space requirements, maintaining production rates while minimizing increased costs associated with line bifurcation.
Implementation Method 1
each pair of rolling mills can deform and stretch the wire rod thus slightly reducing the nominal section thereof
Implementation Method 2
subjecting a steel wire rod with an approximately circular section to a hot-rolling process
Data Source
Figure 1
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Figure 3
AI summary
Wire-rod hot-rolling machine (1) which comprises a plurality of roller- provided rolling units (2) which are arranged one after the other along the wire-rod feeding paths (p); the roller-provided rolling unit (2) being formed by a plurality of rolling-mills assemblies (3) each of which is provided with a pair of opposite, counter-rotating rolling mill rollers (4), which are arranged parallel and adjacent each other; said rolling- mills assemblies (3) being arranged one beside the other, coplanar to a corresponding reference plane locally perpendicular to the feeding paths (p), each at the feeding path (p) of a respective wire rod (b), and are oriented so that the rotation axes (R) of the rolling mill rollers (4) of the various rolling- mills assemblies (3) are locally parallel to one another while intersecting the lying plane of the feeding paths (p) of the wire rods with an inclination angle (3) greater than 5° and smaller than 85°.