Modular Straightening Machine Roller Segments
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Solution Overview
Problem
Existing straightening machines are limited in their ability to adapt to a wide range of product dimensions and strengths due to the need for multiple interchangeable cassette sets or machines, resulting in inflexibility and high costs for machine conversion.
Innovation Solution
The straightening machine is equipped with modular straightening roller segments that can be exchanged individually or in groups, allowing for variable combinations of straightening and support rollers with different diameters and pitches, enabling quick and cost-effective adaptation to various straightening tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple interchangeable cassette sets with different roller configurations are used to expand the straightening range, then the adaptability to different product dimensions and strengths is improved, but the device complexity and investment costs increase
Solution Approach 1:
The straightening machine is divided into multiple independent bearing frames (first, second, third, fourth bearing frames) that can be selectively positioned and engaged. Each bearing frame contains specific straightening rollers and support rollers configured for different product types. This segmentation allows the machine to handle various straightening tasks using only the necessary bearing frames, reducing the need for multiple complete cassette sets while expanding the straightening range.
2Adaptability or versatility
If complete sets of straightening rollers and support rollers are replaced using exchangeable cassettes, then the adaptability to different products is improved, but the tool replacement weight and setup time increase
Solution Approach 1:
Instead of replacing complete cassette sets, the system allows selective positioning of individual bearing frames containing only the specific straightening rollers and support rollers needed for the current product. This reduces the weight that must be handled during setup and decreases the time required for tool changes, while maintaining full adaptability to different product types.
Solution Approach 2:
The bearing frames are designed to be dynamically positionable along the machine structure, allowing them to be engaged or disengaged as needed. This dynamic configuration enables quick setup changes by simply repositioning bearing frames rather than replacing entire roller assemblies, significantly reducing setup time and effort.
3Manufacturing precision
If smaller diameter straightening rollers are used to increase plastic deformation capability, then the straightening effectiveness for thin materials is improved, but the mechanical stress and torque requirements exceed the roller承受能力
Solution Approach 1:
Different bearing frames are equipped with straightening rollers of different diameters optimized for specific material types and thicknesses. For thin materials requiring high plastic deformation, smaller diameter rollers are used in specific bearing frames. For thicker or stronger materials, larger diameter rollers with higher load-bearing capacity are used in other bearing frames. This local optimization allows each roller to operate within its optimal performance range.
Solution Approach 2:
The straightening process is divided into multiple stages using different bearing frames, each with rollers optimized for specific deformation requirements. This segmented approach allows progressive deformation where materials first pass through bearing frames with rollers appropriate for their thickness and strength, distributing the total deformation load across multiple roller sets rather than requiring a single oversized roller.
Data Source
Figure 1~1a
Figure 2
Figure 3
AI summary
With a straightening machine (1) having an allocated straightening roll drive (31) comprising a top bearing frame (2) and a bottom bearing frame (3), in which a plurality of straightening rolls (7) and supporting rolls (8) are held in a cassette-like manner and arranged in an interchangeable manner, a solution is to be created that provides an improved adaptability of a straightening machine to different straightening requirements and straightening areas. This is achieved in that all the straightening rolls (7) and supporting rolls (8) respectively arranged in the top and/or bottom bearing frame (2, 3) are distributed into several straightening roll segments (4-6, 9-30) that are modularly adapted to one another and each configured in the form of an interchangeable cassette, wherein each straightening roll segment (4-6, 9-30) comprises at least one layer of supporting rolls (8) and at least one allocated straightening roll (7).