Mechanical Roll Change Assembly for Automated Wire Rod Stands
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Solution Overview
Problem
Manual roll changing in wire rod rolling with cantilevered rolling stands is labor-intensive, hazardous, and time-consuming, often exceeding operator lifting limits and requiring high-pressure hydraulic tools, posing risks of injury and equipment damage.
Innovation Solution
A roll mounting system utilizing a tapered assembly and torque assembly, integrated with robotic or manipulator systems, eliminates the need for manual handling by providing a mechanical means to securely mount and dismount rolls with reduced weight and complexity, using a tapered sleeve and locking/unlocking nut mechanism to apply force and isolate torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual roll changing is performed by operators, then flexibility and simplicity are maintained, but the process is time-consuming (20 min average, 12 min for experienced operators) and poses safety risks from trapping hazards and burns
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system that uses a combination of mechanical components (tapered assembly, torque assembly) to perform roll mounting and dismounting. The robotic system executes the roll changing process automatically, eliminating manual labor while reducing change time from 20 minutes to a significantly faster automated cycle.
Solution Approach 2:
The roll mounting system is designed to perform its own mounting and dismounting operations through the integrated tapered assembly and torque assembly mechanisms. The system uses self-contained mechanical means where the robotic manipulator operates the mounting tools without requiring external hydraulic systems or manual intervention, enabling autonomous roll changing.
2Force
If high-pressure hydraulic tools are used to mount and dismount rolls, then mounting force is sufficient, but the tools become massive and exceed allowable lifting limits, requiring cranes and manipulators
Solution Approach 1:
The patent replaces high-pressure hydraulic systems with a purely mechanical mounting system. The tapered assembly converts axial force from the locking nut into radial expansion force against the roll, eliminating the need for hydraulic pressure. This mechanical approach reduces tool weight significantly while maintaining sufficient mounting force through the mechanical advantage of the tapered geometry.
Solution Approach 2:
The patent changes the force application method from high-pressure hydraulic force to mechanical force through a tapered mechanism. The locking nut applies axial force that is converted by the tapered assembly into the necessary radial expansion force, changing the physical parameter from hydraulic pressure to mechanical leverage, thereby reducing tool mass.
3Power
If tapered sleeves are used for roll mounting, then mechanical advantage is achieved, but sliding wear reduces service life
Solution Approach 1:
The patent eliminates the traditional sliding contact mechanism and replaces it with a rolling contact approach. The ball bearing assembly is positioned between the tapered sleeve and the locking nut, substituting the sliding friction interface with a rolling contact interface. This maintains the mechanical advantage of the tapered geometry while dramatically reducing wear through the rolling element bearing.
Solution Approach 2:
The patent changes the friction characteristic from sliding friction to rolling friction by introducing ball bearings. This parameter change in the contact mechanism reduces the coefficient of friction and wear rate, thereby extending the service life of the tapered sleeve while maintaining the necessary mechanical advantage for roll mounting.
4Adaptability or versatility
If multiple tools are used for roll handling, mounting, and removal, then specialized functions are achieved, but system complexity increases
Solution Approach 1:
The patent combines multiple specialized tools into a single integrated roll mounting system. The robotic manipulator holds and operates both the tapered assembly and torque assembly as a unified tooling system. The locking nut mechanism integrates the functions of force application, torque transmission, and roll securing into one cohesive mechanism, eliminating the need for separate handling tools, mounting tools, and removal tools.
Solution Approach 2:
The integrated roll mounting system performs multiple functions through a single tooling assembly. The same robotic manipulator and tooling system handle roll removal, roll mounting, and torque application without requiring tool changes. The tapered assembly and locking nut mechanism provide universal functionality for both mounting and dismounting operations, reducing system complexity while maintaining versatility.
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
Enables automated roll changes, reduces the risk of injury, increases the load-carrying capacity of rolling mill stands, and extends the service life of tapered sleeves by minimizing sliding wear, while eliminating the need for high-pressure hydraulics and multiple tools.
Implementation Method 1
a tapered assembly (204) configured to position the roll (201) on the pinion (120)
Implementation Method 2
a ball bearing assembly (203) positioned between the tapered sleeve (204) and the locking and unlocking nut (208)
Data Source
AI summary
A roll mounting system is provided that includes a roll assembly coupled to one or more rolls. The roll assembly is configured to position the one or more rolls using a tapered assembly for mounting or dismounting of the one or more rolls. Also, the roll mounting system includes a torque assembly coupled to the roll assembly. The torque assembly is configured to provide torque to the roll assembly for mounting or dismounting of the one more rolls.