Mechanical Roll Change Assembly for Hydraulic-Free Robotic Mounting
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Solution Overview
Problem
Manual roll changing in wire rod rolling with cantilevered stands is labor-intensive, risky, and inefficient, with high-pressure hydraulic tools often exceeding operator lifting limits and posing hazards, while existing solutions do not adequately address the complexity and weight of roll handling.
Innovation Solution
A mechanical roll change system that integrates a roll mounting system with robotic assistance, utilizing a tapered sleeve assembly, a spring, a tapered sleeve removal and torque isolation ring, and a locking/unlocking nut to automate roll mounting and dismounting, eliminating the need for high-pressure hydraulics and reducing tool complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-pressure hydraulic tools are used to mount and dismount rolls, then the rolling rolls can be secured firmly, but the tool weight exceeds operator lifting limits and poses safety hazards
Solution Approach 1:
The system divides the roll changing operation into distinct phases: robotic positioning and gripping of the roll, followed by mechanical actuation of the tapered sleeve through a nut and bolt assembly. This segmentation allows the heavy hydraulic tools to be replaced with lighter, more manageable mechanical components distributed across multiple elements.
Solution Approach 2:
The patent replaces the high-pressure hydraulic system with a purely mechanical actuation system consisting of a nut, bolt, and tapered sleeve assembly. The robotic manipulator provides positioning, while the mechanical components provide the mounting and dismounting forces, eliminating the need for heavy hydraulic equipment.
2Adaptability or versatility
If manual roll changing is performed by operators, then flexibility and adaptability are maintained, but the process is labor-intensive, time-consuming, and poses safety risks
Solution Approach 1:
The system enables automated self-service roll changing where the robotic manipulator autonomously positions, grips, and facilitates the removal or installation of rolls. The mechanical tapered sleeve system automatically secures or releases the roll through the nut and bolt actuation, eliminating the need for manual operator intervention while maintaining operational flexibility.
Solution Approach 2:
The robotic manipulator acts as an intermediary between the control system and the roll, providing automated positioning and gripping. The mechanical nut-bolt-tapered sleeve assembly serves as an intermediary mechanism that translates simple rotational motion into the complex forces needed for secure roll mounting and easy dismounting.
3Weight of moving object
If cranes and manipulators are used to mount heavy rolls, then the weight limitation is overcome, but the process complexity and time required increase
Solution Approach 1:
The patent merges the positioning, gripping, and actuation functions into a single integrated robotic manipulator system. The mechanical components (tapered sleeve, nut, bolt) are combined into a compact assembly that fits within the rolling mill stand structure, eliminating the need for separate cranes and external manipulators.
Solution Approach 2:
The system transitions from vertical lifting operations requiring cranes to horizontal or radial insertion operations using the robotic manipulator. The tapered sleeve mechanism allows the roll to be pushed axially onto the roll pinion along the dimension of the roll pinion axis, rather than requiring vertical lifting from below.
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 system enables fully automated roll changes, increases the load-carrying capacity of rolling mill stands, reduces the risk of injury, and extends the service life of tapered sleeves by minimizing sliding wear, while allowing for easier and safer handling of heavy rolls.
Implementation Method 1
a spring positioned between the tapered sleeve and the locking/unlocking nut
Implementation Method 2
a tapered sleeve assembly, a spring positioned between the tapered sleeve and the locking/unlocking nut
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A roll mounting system is provided that includes a roll assembly (200) coupled to one or more rolls (201). The roll assembly (200) is configured to position the one or more rolls (201) using a tapered assembly (204) for mounting or dismounting of the one or more rolls (201). Also, the roll mounting system includes a torque assembly (208) coupled to the roll assembly (200). The torque assembly (208) is configured to provide torque to the roll assembly (200) for mounting or dismounting of the one more rolls (201).