Leveling Gap Control for Roller Leveling Machines
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Solution Overview
Problem
Existing part leveling machines face challenges in maintaining a constant leveling gap due to elastic behavior of mechanical components, especially when dealing with thick parts, and struggle with non-rectangular contours and large cut-out areas, requiring extensive testing and adjustments.
Innovation Solution
A method that involves dividing the part into equal partial areas, calculating the bs2 value for each, averaging these values, and using the maximum deflection and yield point to determine an offset for the leveling gap, allowing for blockwise adjustment of rollers to maintain a uniform bending process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the leveling gap is set for thick parts, then the leveling force is sufficient, but the elastic deflection of mechanical components increases significantly
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the nesting depth of leveling rollers based on the calculated bending moment distribution along the part length. For thick parts, the system modifies the nesting depth parameter at different positions to compensate for elastic deflections, maintaining both sufficient leveling force and accurate gap control throughout the leveling process
Solution Approach 2:
The patent implements dynamics by making the nesting depth of leveling rollers variable along the length of the part rather than constant. The system dynamically adjusts the nesting depth according to the calculated bending moment distribution, allowing the leveling gap to adapt to elastic deflections that occur during the leveling of thick parts
2Adaptability or versatility
If conventional leveling machines are used for parts with non-rectangular contours and large cut-out areas, then the machine can process these parts, but extensive testing and adjustments are required
Solution Approach 1:
The patent applies preliminary action by calculating the bending moment distribution and determining the optimal nesting depth profile before the actual leveling process. The system uses the part's geometric data (including non-rectangular contours and cut-out areas) to pre-calculate the required nesting depths, eliminating the need for extensive testing and adjustments during production
Solution Approach 2:
The patent uses copying by creating a digital representation of the part's geometry (including complex contours and cut-out areas) and using this copy to calculate the bending moment distribution. This virtual model allows the system to determine optimal nesting depths without physical trial and error
3Strength
If the nesting depth of leveling rollers is increased to level thick parts, then the bending effect is sufficient, but the elastic deflection of the roller frame increases
Solution Approach 1:
The patent applies parameter changes by adjusting the nesting depth parameter along the length of the part rather than using a uniform depth. The system calculates the optimal nesting depth at each position based on the bending moment distribution, providing sufficient bending effect for thick parts while minimizing the overall impact on roller frame stability
Solution Approach 2:
The patent applies local quality by making the nesting depth local rather than global. Different sections of the part receive different nesting depths according to their specific bending requirements, allowing strong bending effects where needed while maintaining roller frame stability in other areas
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 method improves the leveling results by maintaining a consistent bending process across the machine, reducing the need for extensive testing and adjustments, and achieving better curvature control for parts with complex contours.
Implementation Method 1
the elastic behavior of the mechanical components
Implementation Method 2
the degree of the back-and-forth bending, which must occur in the partially plastic state
Data Source
AI summary
A method for leveling parts in a roller leveling machine, which includes an upper and a lower roller frame, and in which upper and lower leveling rollers are each arranged in a separate leveling roller block, at least one of the leveling roller blocks being variable in its position and angle so that the leveling gap can be adjusted, wherein at least one leveling gap setting device is arranged at the infeed side and at the outfeed side of the leveling machine, and an automatic leveling gap control is provided to set the leveling gap. The method includes determining, for each leveling triangle of the roller leveling machine, an offset value based on the thickness, width, and bending moment of the part to be leveled and characteristics of the leveling machine including a max deflection of the roller frame, and readjusting a setting device of the leveling gap as a function of the leveling triangles mapped onto the part to be leveled as it moves through the leveling gap.