Pipe Mill Drive Roll Thrust Control for Stable Metal Pipe Forming
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Solution Overview
Problem
The existing smart mill technology faces challenges in achieving reliable forming and welding of metal pipes due to instability in thrust generation during the forming process, leading to defects such as meandering or skidding of the material, especially when dealing with varying product dimensions and metal types, as the current system lacks a systematic method for calculating the required forming load and thrust distribution.
Innovation Solution
The implementation of a manufacturing apparatus with non-drive type breakdown rolls and drive rolls arranged in stages, where the drive rolls apply constant thrust using flat rolls with definite reference diameters, and thrust control means, ensuring stable and uniform thrust distribution across multiple stages to maintain consistent forming performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multi-use forming rolls are used to manufacture metal pipes of various diameters, then the versatility and adaptability of the equipment is improved, but the stability and reliability of thrust generation deteriorates
Solution Approach 1:
The forming mill is divided into multiple independent forming sections (first forming section, second forming section, third forming section) each with its own forming rolls. This segmentation allows each section to be optimized for specific forming tasks while maintaining overall system versatility through the multi-use capability of individual rolls.
Solution Approach 2:
The patent implements a thrust control system that dynamically adjusts forming parameters including thrust force, roll position, and forming speed based on the specific pipe diameter and material being processed. This parameter control compensates for the variability introduced by using multi-use rolls, maintaining reliable and stable forming conditions across different production scenarios.
2Adaptability or versatility
If the position of forming rolls is adjusted to accommodate different product dimensions, then the adaptability to various pipe sizes is improved, but the stability of the forming process deteriorates
Solution Approach 1:
The patent incorporates a thrust control system that provides real-time feedback on forming conditions and automatically adjusts roll positions and thrust forces to maintain stable forming parameters. This feedback mechanism ensures that even when rolls are repositioned for different pipe sizes, the forming process remains stable and consistent.
Solution Approach 2:
The forming system employs dynamic adjustment capabilities where roll positions and thrust forces are continuously optimized during the forming process based on detected material behavior and dimensional requirements. This dynamic control maintains process stability despite changes in product dimensions.
3Manufacturing precision
If thrust control is implemented to prevent material defects, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical thrust control mechanisms with a computer-controlled system that uses sensors, actuators, and software algorithms to precisely regulate forming thrust. This substitution reduces mechanical complexity while enhancing manufacturing precision through electronic control and real-time monitoring.
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
This configuration allows for precise control of thrust and forming load, reducing defects and improving the accuracy and efficiency of the forming process, enabling the production of high-quality welded pipes across a range of dimensions and metal types without material pushing or pulling between roll stands.
Implementation Method 1
drive rolls DR that apply thrust to a central portion of the forming target raw material
Implementation Method 2
roll forming of forming a metal strip from a plate shape into a semi-circular shape and a circular shape continuously
Data Source
AI summary
To improve forming performance in a smart mill allowing implementation of required forming by moving a forming tool arranged in a stand of a pipe mill automatically to a predetermined position.Non-drive type breakdown rolls BD exclusive to bending are arranged in multiple stands. Drive roll DR stands exclusive to driving are arranged in stages in front of and behind each DR stand. The drive roll DR is configured to apply thrust to a central portion of a raw material using an upper flat roll and a lower flat roll, and has thrust control means and driving rotation number control means for applying thrust required for passage through the step using the drive rolls DR in multiple stages entirely and controlling the thrust. Applying the thrust under pressure control to the central portion of the material using the upper and lower flat rolls at the DR stand provides a definite roll reference diameter and feeds the raw material at a constant speed and thrust, making it possible to ensure thrust required for various product diameters or thicknesses.