Movable Milling Rollers for Variable-Width Plate Corners
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Solution Overview
Problem
Existing milling apparatuses face challenges when dealing with plate parts of varying widths, requiring roller replacements and inadequate milling force near corners due to cantilevered rollers, which reduces productivity and limits milling to basal parts and acute angle regions.
Innovation Solution
The milling apparatus features movable milling rollers that can be offset to accommodate different widths without replacement, with cantilevered rollers pressed by separate rollers to ensure consistent force application across the entire width and near corners, allowing for reliable milling of differently angled plate parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If milling rollers are replaced to accommodate different plate part widths, then milling coverage is improved, but production time increases and productivity decreases
Solution Approach 1:
The milling rollers are designed with movable positions along the plate part width direction, allowing dynamic adjustment to accommodate different plate widths without replacement. This dynamic positioning capability enables the same roller to adapt to various milling requirements while maintaining continuous production.
Solution Approach 2:
A single milling roller is designed to perform multiple functions by adjusting its position along the width direction, replacing the need for multiple dedicated rollers for different plate widths. This multi-functionality reduces roller replacement operations and maintains productivity.
2Stability of the object's composition
If milling rollers are supported at both ends, then structural stability is improved, but support units interfere with plate parts and prevent milling up to basal parts
Solution Approach 1:
The support function is separated from the milling function. Support units are positioned to provide stability to the milling roller, while the roller itself extends beyond the support units to reach the basal parts of plate parts. This segmentation allows both stability and complete milling coverage.
Solution Approach 2:
The milling roller extends in the width direction beyond the support units, utilizing the third dimension (width direction) to overcome the limitation of end-supported configuration. This dimensional extension allows the roller to mill up to basal parts without compromising structural stability.
3Ease of operation
If milling rollers are cantilevered to avoid interference, then access to plate parts is improved, but sufficient milling force cannot be applied near leading end side
Solution Approach 1:
The milling roller is designed as a cantilevered structure that can dynamically adjust its position along the width direction. This allows the leading end side to access plate parts effectively while maintaining sufficient milling force through controlled positioning and force application.
Solution Approach 2:
The cantilevered milling roller acts as an intermediary between the support units and the plate part basal areas. It transmits milling force from the supported region to the leading end side, enabling effective milling in difficult-to-reach areas while maintaining structural integrity.
4Device complexity
If conventional milling rollers are used, then simple structure is maintained, but regions near corners of acute setting angles cannot be milled
Solution Approach 1:
The milling roller is designed with movable positioning capability along the width direction, allowing it to dynamically adjust to mill corner regions of acute setting angles. This dynamic adjustment maintains relatively simple structure while achieving complete corner coverage.
Solution Approach 2:
The roller system provides different functional qualities at different positions: the supported portion provides structural stability, while the extended leading end portion provides access to corner regions. This local differentiation enables both simple structure and complete corner milling coverage.
Data Source
AI summary
A milling apparatus includes a plurality of milling roller units each including one milling roller that is made contact with, by pressing, one surface of one of a plurality of differently angled plate parts of an elongated metal milling material and another milling roller that is made contact with another surface of the plate part by pressing. At least one of the milling roller units mills a plate part different from a plate part milled by any other milling roller unit. A plurality of the milling roller units configured to mill an identical plate part are installed in a longitudinal direction of the plate part. The one milling roller and the other milling roller of at least one of the milling roller units are movable in axial directions thereof.