Hydraulic Cross-Rolling Mill for Real-Time Rolling Gap Control
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Solution Overview
Problem
Existing cross-rolling mills cannot adjust the rolling gap during the rolling process, leading to disturbances in the rolling gap geometry and symmetry, resulting in defects in the hollow block production, such as increased eccentricities in the wall thickness.
Innovation Solution
The implementation of hydraulic actuators, connected to the working rollers and mandrel, allows for dynamic adjustment of the rolling gap and alignment of the rollers during the rolling process, enabling real-time compensation of disturbance variables using a measuring device and evaluation unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If mechanical spindle drives are used to adjust the rolling gap, then the rolling gap can be adjusted prior to and after the rolling process, but the rolling gap cannot be adjusted during the rolling process
Solution Approach 1:
The patent replaces mechanical spindle drives with hydraulic actuators (hydraulic capsules) to adjust the rolling gap. This substitution enables continuous adjustment during the rolling process, as hydraulic systems can respond dynamically and continuously, unlike mechanical spindles which are limited to discrete adjustment positions and require stopping the process.
Solution Approach 2:
The patent implements dynamic adjustment of the rolling gap during the rolling process using hydraulic actuators. The system continuously monitors the rolling gap and automatically adjusts it in real-time to compensate for disturbances, transforming the static adjustment capability into a dynamic control system that adapts throughout the rolling operation.
2Manufacturing precision
If hydraulic actuators are used to dynamically adjust the rolling gap, then real-time compensation of disturbance variables is enabled, but the device complexity increases
Solution Approach 1:
The patent implements a feedback control system where sensors continuously monitor the rolling gap and wall thickness parameters, and this information is fed back to the control unit which automatically adjusts the hydraulic actuators. This closed-loop feedback mechanism enables real-time compensation of disturbances while maintaining manufacturing precision, justifying the increased device complexity through improved product quality.
Solution Approach 2:
The system performs self-adjustment by automatically detecting rolling gap deviations and compensating for them without external intervention. The control unit continuously monitors the rolling process parameters and autonomously commands the hydraulic actuators to maintain the optimal rolling gap, enabling the system to self-correct disturbances during rolling.
3Stability of the object's composition
If working rollers are firmly connected to the roll stand, then minimal movement under load occurs, but the previously set arrangement of working rollers and mandrel is lost due to stand expansion under enormous rolling forces
Solution Approach 1:
The patent applies preliminary counter-actions by using hydraulic actuators to pre-compensate for the expected stand expansion under rolling forces. The system anticipates the distortion and applies opposing adjustment forces through the hydraulic capsules to maintain the correct rolling gap geometry, preventing the loss of symmetry before it occurs.
Solution Approach 2:
The patent dynamically changes the position parameters of the working rollers using hydraulic actuators to compensate for stand expansion. By continuously adjusting the rolling gap dimensions and roller alignment in response to measured distortions, the system maintains manufacturing precision despite the physical expansion of the roll stand under enormous rolling forces.
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 solution enables precise and dynamic compensation of rolling gap modifications and stand expansion, ensuring consistent hollow block quality by minimizing defects and maintaining symmetry during the rolling process.
Implementation Method 1
hydraulic actuators, preferably hydraulic capsules, are provided to modify the rolling gap, preferably also the alignment of the rolling axis of at least one of the working rollers relative to the block
Data Source
AI summary
A cross-rolling mill for rolling a block over a mandrel forms a hollow block. It includes a plurality of working rollers, each of which exerts a substantially radially aligned rolling force onto the block. The working rollers are supported in a roll stand, and the gap between the working rollers and preferably also the alignment of the rolling axis of at least one of the working rollers relative to the block can be modified. Hydraulic actuators, preferably hydraulic capsules, are provided in order to modify the rolling gap and preferably also the alignment of the rolling axis of at least one of the working rollers relative to the block.