Segmented Laying Head Pathway With Airfoil Supports for Wear Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The increased delivery speeds in rod rolling mills lead to excessive wear of laying head pathways and split rings, resulting in unstable ring patterns and increased downtime, posing hazards and economic burdens.
Innovation Solution
A laying head assembly with a pathway defined by a laying head pipe supported by airfoil-shaped structures, featuring a limited number of segments and voids, which reduces noise, power consumption, and maintenance time by minimizing wear and allowing for quicker replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If delivery speed is increased to improve productivity, then productivity increases, but wear on laying head components increases
Solution Approach 1:
The pathway is divided into multiple replaceable segments that can be individually replaced without replacing the entire pathway assembly. This segmentation allows for quicker maintenance and reduces downtime while handling high-speed delivery demands.
Solution Approach 2:
The laying head components are designed with dynamic characteristics that allow them to better withstand high-speed operational forces. The airfoil-shaped support structures are optimized for dynamic loading conditions at increased delivery speeds.
2Reliability
If pathway and split ring are replaced frequently to maintain reliability, then component reliability is improved, but loss of time increases
Solution Approach 1:
The pathway is segmented into multiple sections that can be replaced independently. When wear occurs, only the affected segments need to be replaced rather than the entire pathway, significantly reducing replacement time while maintaining ring pattern stability.
Solution Approach 2:
Worn pathway segments are designed to be easily discarded and replaced with new or refurbished segments. The modular design allows for quick removal and installation, minimizing mill downtime.
3Device complexity
If traditional support structures are used, then device complexity is reduced, but power consumption increases
Solution Approach 1:
The support structures are designed with airfoil-shaped cross-sections that are asymmetric in form. This asymmetric geometry is optimized to reduce drag and power consumption while the structures rotate with the laying head, creating a more energy-efficient system.
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 solution decreases noise and power consumption, reduces maintenance time by 36%, and minimizes wear on the laying head components, thereby enhancing operational efficiency and safety while reducing downtime and maintenance costs.
Implementation Method 1
Each of the support assemblies can include a support structure that is generally shaped like an air foil. As the laying head rotates at high speeds (RPMs), the shape of the support structures can substantially decrease the noise generated by the laying head assembly
Implementation Method 2
the shape of the support structures can substantially decrease the power consumed by an electric motor coupled thereto
Data Source
AI summary
A laying head assembly for the formation of coils is disclosed and can include a laying head configured to rotate about an axis, a pathway defining an enclosed conduit configured to contain an elongated material, the pathway extending in a helical path around the laying head, and at least one support structure coupling the pathway to the laying head, wherein at least one of the one or more couplings have an asymmetrical cross-sectional shape.