Movable Weld Splatter Containment Covers for Rolling Mills
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Solution Overview
Problem
Current weld splatter containment devices in rolling mills fail to achieve complete enclosure of the flash phase zone, leading to material losses and frequent maintenance stops due to incomplete splatter containment and ineffective cleaning mechanisms.
Innovation Solution
A weld splatter containment device with movable upper and lower covers controlled by actuators, featuring a buffer and guillotine shear for automatic cleaning, allowing for adjustable positioning to eliminate gaps between covers and billets, ensuring complete enclosure and preventing short circuits, while the buffer can effectively clean the entire inner surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the covers are positioned close to the billets to eliminate gaps, then splatter containment is improved, but short circuits may occur between the covers and billets
Solution Approach 1:
The covers are made movable rather than fixed, allowing them to dynamically adjust their position relative to the billets. During the flash phase, the covers approach the billets to eliminate gaps and contain splatter. During maintenance and cleaning phases, the covers move away to prevent short circuits and allow buffer access. This dynamic positioning resolves the contradiction between splatter containment and electrical safety.
Solution Approach 2:
The containment device is divided into separate movable covers (upper and lower) that can be independently controlled. This segmentation allows different parts of the system to perform different functions at different times - covering during welding and opening during maintenance - thereby resolving the contradiction between containment effectiveness and operational safety.
2Ease of manufacture
If the buffer is designed to clean the inner walls of the upper cover, then cleaning effectiveness is improved, but the buffer cannot reach the entire surface due to the tilted conformation
Solution Approach 1:
The upper cover is made rotatable rather than fixed in a tilted position. During cleaning operations, the cover rotates to a horizontal position, allowing the buffer to effectively clean the entire inner surface including areas that would be inaccessible in a tilted configuration. This dynamic repositioning resolves the contradiction between maintaining structural design and achieving complete cleaning coverage.
3Ease of operation
If manual cleaning of the upper cover is performed, then cleaning is achieved, but production must be stopped about every two hours
Solution Approach 1:
The system incorporates an automatic cleaning mechanism where a buffer automatically cleans the inner surface of the upper cover during designated cleaning phases. This self-service cleaning operation eliminates the need for manual intervention and production stoppages, thereby resolving the contradiction between effective cleaning and continuous production.
Solution Approach 2:
The cleaning operation is integrated into the periodic cycle of the welding machine, with the buffer activated at appropriate intervals to clean the covers. This periodic automatic cleaning maintains productivity by avoiding unplanned stoppages while ensuring the covers remain clean for effective operation.
4Object-affected harmful factors
If the weld splatter containment device is used, then splatter is contained, but the buffer becomes compromised by splatter accumulation
Solution Approach 1:
The buffer performs preliminary cleaning of the upper cover inner surface after each welding operation or at designated intervals. By proactively removing splatter before it accumulates to compromising levels, the buffer maintains its functionality and prevents the contradiction between effective containment and buffer degradation.
Solution Approach 2:
The cleaning function operates continuously or periodically rather than intermittently, ensuring that splatter is constantly removed from the buffer and cover surfaces. This continuous maintenance action prevents splatter accumulation that would compromise buffer functionality, resolving the contradiction between containment effectiveness and component reliability.
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 device achieves near-total closure of the flash phase zone, reducing material losses and eliminating the need for manual maintenance, thereby maintaining continuous production and improving operational efficiency by ensuring the welding machine remains free from splatter and residues.
Implementation Method 1
allows the lower cover (101) to move away from and/or approach the welding zone, carrying out a respectively lowering and/or raising movement which follows a circular trajectory portion
Implementation Method 2
the upper cover (103) is controlled in moving away from and/or approaching the welding zone by means of the second actuator (104), it too, in the illustrated embodiment, made by means of a lever system, which guides it respectively in a raising and/or lowering movement along a circular trajectory portion
Implementation Method 3
the buffer (105), during the descent phase, exerts a cleaning action over the entire surface of the cover (103), effectively removing the welding residues
Implementation Method 4
The guillotine shear (107) can be inserted or extracted from the upper cover (103) in a manner such to form, when inserted, a protection of the buffer (105) during the flash phase
Implementation Method 5
The locking clamps, also called electrode holders, bring suitable current intensity in order to achieve the superheating and melting of the two parts in contact with each other
Implementation Method 6
the two parts in contact with each other... achieve the superheating and melting of the two parts in contact with each other
Data Source
AI summary
A weld splatter containment device for use in rolling mills includes a lower cover and an upper cover, both controllable in approaching and moving away from a welding zone so as to substantially surround the welding zone when the lower and upper covers are situated in a position close to the welding zone. The lower cover is controlled in approaching and moving away from the welding zone along a first circular trajectory portion and the upper cover is controlled in approaching and moving away from the welding zone along a second circular trajectory portion.