Hydraulic Backing Roller for Precise Strip Flatness Control
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Solution Overview
Problem
The existing backing roller technology using a rack and pinion mechanism for shape control in cold-rolled strip production is prone to reduced adjustment accuracy due to wear, causing vibrations and inefficiencies in production, and is cumbersome for disassembly and maintenance, affecting the flatness and surface quality of ultra-thin metal strips.
Innovation Solution
A hydraulically controlled backing roller design featuring a mandrel with screwdown gears and saddle ring sets, where an inner eccentric ring is driven hydraulically to induce deflection deformation, transmitted through a backing bearing to control strip flatness, offering improved accuracy, flexibility, and ease of maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a rack and pinion mechanism is used to control the backing roller, then the adjustment mechanism is mechanically simple, but the adjustment accuracy decreases due to wear and tear, causing vibration
Solution Approach 1:
The patent replaces the mechanical rack and pinion engagement system with a hydraulic drive system. The hydraulic cylinder directly drives the outer eccentric ring through a piston rod, eliminating the meshing gears and rack that are prone to wear. This substitution maintains mechanical simplicity while dramatically improving adjustment accuracy and eliminating vibration caused by gear wear.
Solution Approach 2:
The patent introduces a hydraulic drive system where a hydraulic cylinder with a piston rod connects to the outer eccentric ring. Hydraulic fluid pressure moves the piston rod to rotate the outer eccentric ring, providing precise control of the backing roller's position without mechanical gear engagement. This hydraulic mechanism resolves the contradiction by offering both simplicity and high precision.
2Ease of operation
If a rack and pinion engaging method is used, then the backing roller can be controlled, but disassembly and replacement become inconvenient, reducing production efficiency
Solution Approach 1:
By replacing the complex meshing gear system with a hydraulic piston rod connection, the patent creates a system that is both easy to control and easy to maintain. The hydraulic connection points are accessible and can be quickly disconnected, allowing rapid replacement of the backing roller assembly without disassembling gear mechanisms, thus improving production efficiency.
Solution Approach 2:
The patent designs the backing roller assembly as a separable unit that can be independently removed and replaced. The hydraulic cylinder and piston rod form a modular control unit that can be quickly disconnected from the roller, enabling rapid maintenance and replacement operations that minimize production downtime.
3Adaptability or versatility
If multiple backing rollers are placed in the direction of the mandrel with rack reduction, then segmented action is achieved for shape control, but the mechanism becomes complex and prone to wear
Solution Approach 1:
The patent replaces multiple mechanical rack and pinion reduction mechanisms with individual hydraulic drive systems for each backing roller. Each roller has its own hydraulic cylinder that can be independently controlled, achieving segmented shape control without the complexity and wear problems of multiple gear mechanisms.
Solution Approach 2:
The patent uses a universal hydraulic drive system that can be applied to multiple backing rollers along the mandrel. The same hydraulic control architecture serves all rollers, providing segmented control capability while simplifying the overall mechanical structure compared to individual gear mechanisms for each roller.
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 hydraulically controlled backing roller provides enhanced control accuracy, reduced maintenance costs, and increased production efficiency with improved flatness control and reduced noise, while being simpler and more cost-effective than traditional systems.
Implementation Method 1
the outer eccentric ring of the backing roller is driven by the piston rod rack at the output end of the convexity hydraulic cylinder
Implementation Method 2
The outer eccentric ring of the backing roller is driven by the piston rod rack
Implementation Method 3
so that the mandrel has the deflection deformation. The deflection deformation is transmitted to the work rolls through the tower roll system
Data Source
AI summary
A hydraulically controlled backing roller includes a mandrel, two cover plates which are installed at two ends of the mandrel through screws respectively, and two screwdown gears which are installed at two end portions of the mandrel respectively. The two screwdown gears are engaged with an output rack of a screwdown hydraulic cylinder, multiple saddle ring sets are sleeved on the mandrel at equal intervals, a saddle ring of each of the saddle ring sets is fixed with a frame through a fan-shaped plate, a backing bearing is provided between two adjacent saddle ring sets; an inner eccentric ring of the each of the saddle ring sets is driven to rotate by hydraulic driving, so that the mandrel has a deflection deformation, and the deflection deformation is transmitted to other adjacent rollers through the backing bearing.