Compact Leveling Machine for Thick Metal Strips
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Solution Overview
Problem
Existing leveling machines for thick metal strips are cumbersome and heavy due to the stacking of structural members and cylinders, which complicates the process and increases the height and volume of the machines, making them inefficient for handling very wide and thick strips.
Innovation Solution
A leveling machine design that eliminates the need for conventional pressure frames and horizontal cross members by using a flexible leveling cassette with varying thickness zones and a system of cylinders to move the upper cassette vertically, allowing for a more compact and lightweight structure while maintaining the ability to offset bending caused by strip passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional pressure frames and horizontal cross members are used to support the upper leveling cassette, then the structural strength and stability are sufficient, but the machine becomes heavy and bulky with increased volume
Solution Approach 1:
The patent removes the conventional pressure frame and horizontal cross members from the structure. The upper leveling cassette is directly supported by vertical beams, eliminating unnecessary structural components while maintaining the required strength and stability for leveling operations.
Solution Approach 2:
The support structure is segmented into discrete vertical beams that directly carry the upper cassette, replacing the monolithic pressure frame structure. This segmentation allows for reduced material usage while maintaining local strength where needed.
2Ease of operation
If multiple cylinders are stacked to support and move the upper cassette, then the vertical movement and bending correction functions are achieved, but the machine height and complexity increase
Solution Approach 1:
The patent merges the bending correction function and the vertical movement function into a single cylinder system. The cylinders are positioned to simultaneously perform both functions, eliminating the need for stacked cylinder arrangements and reducing overall machine height.
Solution Approach 2:
The cylinders are designed to perform multiple functions: supporting the upper cassette, enabling vertical movement for gap adjustment, and providing bending correction. This multi-functionality reduces the number of separate components needed.
3Stability of the object's composition
If a rigid pressure frame structure is used, then the stability during operation is maintained, but the machine weight increases by tens of tons
Solution Approach 1:
The heavy pressure frame is completely removed from the structure. The patent achieves operational stability through a simplified configuration where vertical beams directly support the upper cassette, eliminating tens of tons of unnecessary structural weight.
Solution Approach 2:
The structural design parameters are changed from a massive rigid frame to a leaner beam-supported configuration. This parameter change maintains stability while dramatically reducing weight through optimized structural efficiency.
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 design results in a significantly lighter and more compact leveling machine that reduces the mass and volume, enabling precise movement and efficient leveling of strips without the need for heavy and complex cylinder systems, thus improving operational efficiency and reducing the overall weight by tens of tons.
Implementation Method 1
hydraulic closing cylinders bearing on one side against the upper beams and on the other against the pressure frame
Implementation Method 2
correction cylinders 7 placed between the pressure frame 4 and the upper leveling cassette 5a
Data Source
AI summary
A machine for leveling a strip of material contains a lower stationary back plate from which extends vertical beams located on either side of a longitudinal axis. A lower stationary leveling chassis and an upper leveling chassis are provided. Each chassis contains spaced apart rollers. An upper stationary back plate is rigidly secured to the upper end of each beam, and a moving coupling device couples the upper leveling chassis to the upper back plate. A device allows a vertical translational movement of the upper leveling chassis in relation to the upper stationary back plate between a rest position where the rollers of the upper leveling chassis are moved away from rollers of the lower leveling chassis and a leveling position where rollers of the upper leveling chassis are moved towards rollers of the lower leveling chassis and the strip is forced to travel along an undulating path.