Laser Surface Restoration of Rolling Cylinders With Profile Detection
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Solution Overview
Problem
Existing methods for restoring the surface of rolling cylinders in rolling mills, such as grinding with a grinding wheel, are energy-inefficient, costly, generate significant waste, and require high thermal energy, leading to high operational costs and environmental concerns.
Innovation Solution
A laser-based apparatus and method for grinding the lateral surface of cylindrical bodies, utilizing pulsed laser beams with high peak power for efficient material removal, coupled with a profile detector and gas nozzle to optimize the grinding process and minimize waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional grinding with a grinding wheel is used to restore the surface of rolling cylinders, then the surface roughness can be restored to the required tolerance, but the energy consumption is high and significant waste is generated
Solution Approach 1:
The patent replaces the conventional mechanical grinding system with a laser-based processing system. The laser beam directly作用于 the cylinder surface to remove material and restore surface roughness, eliminating the need for mechanical contact between a grinding wheel and the cylinder. This substitution significantly reduces energy consumption while maintaining manufacturing precision for surface restoration.
Solution Approach 2:
The patent utilizes controllable laser parameters (power, pulse duration, scanning speed) to optimize the material removal process. By adjusting these parameters, the system achieves the required surface roughness restoration with minimal energy input compared to conventional grinding, which operates at fixed high power levels regardless of the actual material removal needs.
2Manufacturing precision
If conventional grinding with a grinding wheel is used to restore the surface of rolling cylinders, then the surface defects can be eliminated, but significant waste material and cooling fluid are generated
Solution Approach 1:
The laser-based system replaces mechanical grinding, eliminating the generation of wet sludge waste that combines metal chips, emery grains, binder resin particles, and emulsified cooling fluid. The laser process produces minimal waste in the form of vaporized or ablated material that can be more easily managed and disposed of.
Solution Approach 2:
The laser processing method removes material in a controlled manner, vaporizing or ablocking only the necessary surface layer to eliminate defects and restore roughness. This precise material removal minimizes waste generation compared to conventional grinding which removes excessive material along with the required surface layer.
3Manufacturing precision
If conventional grinding with a grinding wheel is used to restore the surface of rolling cylinders, then the surface roughness can be restored, but high thermal energy is required leading to high operational costs
Solution Approach 1:
The patent replaces the thermally intensive mechanical grinding process with a laser-based system that uses optical energy for material removal. The laser beam delivers energy directly to the surface in a highly localized and controllable manner, reducing overall thermal energy consumption and associated operational costs while achieving the same surface restoration results.
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 laser-based method reduces energy consumption, minimizes waste generation, and lowers operational costs while effectively restoring the surface characteristics of rolling cylinders, enhancing processing efficiency and reducing environmental impact.
Implementation Method 1
A laser-based apparatus and method for grinding the lateral surface of cylindrical bodies, utilizing pulsed laser beams with high peak power for efficient material removal
Data Source
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Figure 5~6a
AI summary
Apparatus (10) and method for surface processing of cylindrical bodies (1), particularly for surface restoration of laminating cylinders. The apparatus includes a workstation (100) configured to receive a cylindrical body having a lateral surface movable by rotation about an axis of rotation K, a laser emitter (600) cooperating with the workstation and configured to emit at least one laser beam, a profile detector (700) configured to detect a detected surface profile of the lateral surface of the cylindrical body, and a control unit (15) operatively configured to perform at least one procedure for restoring the lateral surface of the cylindrical body. The restoration procedure includes a procedure for detecting the surface profile of the cylindrical body, including a step of comparing the detected surface profile with a target surface profile, and a removal procedure including a step of emitting the laser beam on the cylindrical body to remove metallic material and to obtain the target surface profile.