Push-Pull Roll Displacement Device for Rapid Stand Changes
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Solution Overview
Problem
Current methods for changing rolls in rolling mills are either slow and labor-intensive, leading to productivity losses and safety risks, especially in fractional production settings where quick roll adaptation is crucial for varying product specifications.
Innovation Solution
A push-pull roll displacement device that allows for simultaneous extraction and loading of rolls, using fastening means on both sides of the stand to automate the process, enabling rapid roll changes without stopping the mill and ensuring safety by automating operations near the rolling mill.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a pushing displacement device is used to extract worn rolls and insert new rolls, then the roll changing operation can be automated, but the operation must be carried out very slowly to avoid uncontrollable inertia and potential damage to rolls, bearings, or stand parts
Solution Approach 1:
The roll changing operation is divided into distinct phases: positioning the new roll, coupling it to the worn roll, executing the push operation, and then decoupling. This segmentation allows the system to automate the operation while controlling speed at critical moments, particularly during coupling and decoupling phases where precision is needed.
Solution Approach 2:
The new roll is positioned and coupled to the worn roll before the push operation begins. This preliminary positioning ensures that when the push operation starts, all components are correctly aligned, allowing for faster execution without risking misalignment damage. The coupling mechanism is prepared in advance to handle the forces that will be applied.
2Reliability
If the rolling mill is stopped to change rolls, then the roll changing operation can be performed safely, but productivity is reduced due to idle time
Solution Approach 1:
The push-type displacement device allows the roll changing operation to be performed while the mill remains operational or can be quickly restarted. The automated push mechanism enables continuous or near-continuous production by minimizing the interruption time, as the new roll is already positioned and coupled before the actual extraction begins.
Solution Approach 2:
The new roll is positioned and coupled to the worn roll before the mill is stopped or during the stopping phase. This preliminary preparation ensures that when the mill stops, the replacement is already ready to go, minimizing idle time and allowing for rapid resumption of operations.
3Device complexity
If manual operations are used for roll changing, then the process is simpler, but the operation is labor-intensive and poses safety risks to staff
Solution Approach 1:
The displacement device is designed to perform the roll extraction and insertion operations automatically without requiring manual intervention during the critical push phase. The system serves itself by using the new roll as the actuating element to push out the worn roll, eliminating the need for workers to be in dangerous positions near the rolling mill during operation.
4Ease of operation
If the stand is opened to change rolls, then the operation can be performed, but the operation becomes more complex and time-consuming
Solution Approach 1:
The new roll is positioned and coupled to the worn roll while the stand is still closed or in the process of opening. This preliminary coupling eliminates the need to fully open the stand just to position the new roll, as the coupling occurs during the transition phase, reducing the time the stand needs to remain open.
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 method significantly reduces idle time, enhances safety by automating roll-changing operations, and allows for quick adaptation to varying product specifications, improving productivity in fractional production environments.
Implementation Method 1
The actuation of this device enables to push a new roll in order to load it inside the stand. The new roll pushes in turn the worn roll initially in the stand in order to unload it outside the stand.
Implementation Method 2
the working rolls are not directly driven into rotation, but by means of back-up rolls, which are driven into rotation by associated driving means, and drive in turn by friction the working rolls in contact with the product to be rolled
Data Source
AI summary
Method for changing working rolls of a roll stand provided with a roll displacement device located on the first side of the stand moving a roll along a loading axis (C, C′). Each has fastening means at a first end towards the first side and matching fastening means at a second end towards the second side of the stand opposite to the first side. Matching fastening means are on the displacement device. The substitute roll can be placed on either side of the stand. The displacement device operates by pulling when the substitute roll is on the second side simultaneously extracting the roll to be replaced towards the first side and loading the substitute roll from the second side; and, vice versa, by pushing when the substitute roll is on the first side of the stand.The various fastening means and matching fastening means are respectively coupled and decoupled.