Mandrel-Free Wheel Rolling Drive Segmentation

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Solution Overview

Problem

Mandrel-free rolling of wheels and disks results in high wear and undesirable slip between web rollers and blanks due to sole reliance on friction for rotation, affecting machining accuracy.

Innovation Solution

Equipping tapered rollers and the main roller with drive devices to independently control rotation, allowing the main roller and cone rollers to assist in setting the blank in rotation, reducing friction and slip during the acceleration phase, and adjusting drive mechanisms to synchronize speeds for reduced wear.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If web rollers alone are used to rotate the blank via friction, then the rolling process can be simplified, but wear on web rollers increases and machining accuracy deteriorates due to slip

Engineering Contradiction:

Improverolling process simplicityVSAvoidmachining accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The rotation function is segmented from the web rollers and assigned to dedicated drive devices on the main roll and cone rollers. This allows each component to have a specialized function: web rollers for forming and drive rollers for rotation, reducing wear on web rollers while maintaining precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The main roll and cone rollers act as intermediary drive elements that transfer rotational motion to the blank through controlled friction, reducing the burden on web rollers and minimizing slip during acceleration phases.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If web rollers alone accelerate the blank through friction, then the drive system can be simpler, but wear on web rollers increases

Engineering Contradiction:

Improvedrive system complexityVSAvoidweb roller service life

Core Design Contradiction:

Device complexityVSDuration of action of stationary object

Solution Approach 1:

The acceleration function is segmented from the web rollers and assigned to drive devices on the main roll and cone rollers. This division of labor reduces the wear burden on web rollers, extending their service life while keeping the overall drive system manageable through modular independent control.

Inventive Principle:

Principle #1Segmentation

3Duration of action of stationary object

If drive devices are added to main roll and cone rollers, then wear on web rollers is reduced, but device complexity increases

Engineering Contradiction:

Improveweb roller service lifeVSAvoiddrive system complexity

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

The main roll and cone rollers serve dual functions: they perform their traditional forming functions and simultaneously provide drive functions through added drive devices. This multi-functionality reduces wear on web rollers without requiring entirely separate drive systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The drive devices on the main roll and cone rollers can be independently controlled and adjusted during the rolling process, allowing dynamic optimization of wear distribution and enabling the system to adapt to different rolling conditions and blank masses.

Inventive Principle:

Principle #15Dynamics

4Device complexity

If web rollers are the sole drive source, then the control system can be simpler, but slip occurs reducing machining accuracy

Engineering Contradiction:

Improvecontrol system complexityVSAvoidmachining accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The rotation control function is segmented from the web rollers and assigned to dedicated drive devices on the main roll and cone rollers. This allows independent control of rotation and forming functions, reducing slip and improving accuracy while maintaining manageable control complexity through modular operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The drive devices can be controlled independently and adjusted during the rolling process based on feedback from sensors monitoring blank position and roller speeds, enabling real-time correction of slip conditions and maintenance of machining accuracy.

Inventive Principle:

Principle #23Feedback

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

Significantly reduces wear on web rolls and minimizes slip, enhancing machining accuracy by distributing rotational stress and maintaining synchronized speeds between components.

Implementation Method 1

the friction and the slippage between the blank and the web rolls can be reduced

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

The rotary movement of the standing rollers is transmitted to the blank via friction, which also causes it to rotate

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentEP2457676B1Method and rolling device of mandrel-free rolling of wheels and discs

Publication Date: 2012.11.07 SCHULER SMG GMBH & CO KG

Figure 1~2

AI summary

The rolling device (10) has a roller frame (11), where a blank (R) is inserted around a rotational axis (D2) in a rotating manner. The rod rollers (16) are driven in rotating manner by a drive device (17). A tapered rollers (15) and main roller (13) have other drive devices (18,19) for turning drive. An independent claim is also included for a method for loose bolt rolling of wheels and discs.